ON BOARD MEASUREMENTS OF SCRUBBER

PERFORMANCE ON VESSELS

Tadeusz Borkowski
Maritime University of Szczecin
Contents:
1. Background – wet scrubber types
• Wet Scrubbing – classic functional principle of operation
• Wet and Dry Scrubbing – current approach
2. Exhaust Gas Cleaning System – list of manufacturers
3. EGCS installations number in service
4. Regulatory requirements
5. On board survey methodology
6. Ship’s routine voyage and relevant EGCS operation
7. Exhaust emission in open loop mode
8. Sea and washwater parameters in open loop mode
9. Exhaust emission and sea water parameters in closed loop mode
10. Conclusions
Wet Scrubbing – classic functional principle of operation

Wet scrubbers

Exhaust Exhaust
Exhaust
outlet outlet
outlet

Washwater
inlet

Packed
Washwater
Bed
Washwater inlet
Exhaust
inlet inlet Exhaust
inlet
Exhaust
inlet Packed
Bed
Washwater
outlet

Washwater Washwater
outlet
outlet

Tower Bath Packed bed

 Wet and Dry Scrubbing – current approach

Wet scrubbers Dry scrubber

Exhaust
outlet Exhaust
Washwater inlet Exhaust outlet outlet

Exhaust
inlet

Washwater
inlet Exhaust inlet

Membrane
Venturi SO2
outlet

Exhaust
Washwater Washwater outlet inlet
outlet

Venturi Cyclonic Membrane

Exhaust Gas Cleaning System – list of manufacturers

WARTSILA
WÄRTSILÄ MOSS
AEC MARITIME

CHINA
ANDRITZ AIR ENVIRONMENTAL ECOSPRAY
POLLUT. CONTROL PROJECT LANGH TECH PURETEQ
TECHNOLOGIES

SAACKE MARINE
ALFA-LAVAL CLEAN MARINE FUJI ELECTRIC MAN DIESEL SYSTEMS

CR OCEAN MARINE EXHAUST TRITON EMISSION

BABCOCK NOELL ENGINEERING LAB SOLUTIONS INC.
SOLUTIONS

DUPONT BELCO
BLUESOUL CLEAN AIR IONADA™ MUNTERS YARA MARINE
EGCS installations number in service

Scrubber units in service

Ships equipped with EGCS
600

TANKER 500
39
400
SERVICE 2
300
RORO SHIP 113
200
GENERAL CARGO 25
100
CRUISE SHIP 110 0
CONTAINER… 27
BULK CARRIER 24

0 50 100 150

Source: IHS Maritime 2017 Source: IHS Maritime 2017

Estimated number of scrubber units onboard

In Service 843
Keel laid 13
Launched 16
On order and not commenced 21
Under construction 2
Total 895
Source: IHS Maritime 2017
Regulatory requirements
IMO Resolutions: MEPC.130(53), MEPC.170(57) and MEPC.184(59) 2009;
Guidelines for Exhaust Gas Cleaning Systems, adopted on 17 July 2009
Exhaust emissions compliance limits
For EGC systems operating on conventional fuel oils, exhaust emission compliance
with the equivalent fuel oil sulphur content is verified from the measured SO2/CO2
concentration ratio
Fuel Oil Sulfur Content Emission Ratio
(%m/m) SO2 (ppm)/CO2 (%v/v)
0.10 4.3

Washwater discharge and limits

1. pH criteria
The pH of the discharged wash water from the scrubbing process should
be no lower than 6.5 units
2. PAH* concentration
The washwater maximum continuous PAH concentration is not to be
greater than 50 μg/Ltr above inlet water PAH concentration
3. Turbidity
The turbidity of the EGC unit washwater should not exceed 25 NTU
above
the inlet
*Polycyclic waterHydrocarbons
Aromatic turbidity
On board survey methodology

EGCS
Operational survey

EGCS EGCS EGCS Ship

documenation compliance operational data Propulsion

SOx Emissions
EGCS Exhaust emissions Ship s speed
Compliance Plan - SECP
efficiency
Washwater
EGCS Technical Main engine power
EGCS discharge
Manual - ETM
running
cost Operating Auxiliary electric
Onboard Monitoring
parameters load
Manual - OMM
EGCS Electrical
Electronic Logging Fuel oil consumption
reliability consumption
System - EGC

NaOH consumption
Emission
factors
Sludge discharge
Ship’s propulsion and EGCS layout
Multiunit Hybrid Exhaust Gas Cleaning
System
Ship’s Diesel-Electric main/auxiliary SO2
CO2
SO2
CO2
SO2
CO2
SO2
CO2
propulsion
4.5 MW

4.5 MW

4.5 MW

4.5 MW
G G G G
~ ~ ~ ~

6.6 kV 6.6 kV

440 V 440 V
6.5 MW

6.5 MW
PEM

PEM

Main Engine specification

Type MaK 6M 552 C
Engine 4 stroke, direct injection
Rated power 4500 kW
Rated speed 500 rpm
Bore 450 mm
Stroke 520 mm
Exhaust gas
temperature - max 650 C0
 Ship’s routine voyage and relevant EGCS operation

20 20000 14000

12000 Steaming
Full steaming Open Loop

Propulsion power [kW]

15 15000 10000

Observations
Ship speed [kts]

8000 Port
Manoeuvring approaching
10 10000 6000 Open Loop Open Loop

4000
5 5000
2000
Ship speed
Propulsion power 0
0.0 4.5 9.0 13.5 18.1 22.6 27.1
0 0
21-Jul 21-Jul 21-Jul Ship's speed [Kts]

24 10
Steaming - Open Loop At berth - Closed Loop
20

EGCS running hours [hr]

8
Fuel oil
Type Marine fuel RMG 380 16

OP/CL Ratio
6
Density 150C 981.0 kg/m3
12
Viscosity 500C 375 cSt
4
Water % 0 8

Sulphur % 1.75 2
4

0 0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Open Loop/Closed Loop Ratio
Day of the month
 EGCS in open loop mode - compliance monitoring
Engine sulphur combustion chemistry:

Exhaust gas S + O2 → SO2 ~ 95%

outlet SO2 + ½O2 → SO3 ~ 5%
De-plume
unit SO2
CO2
SOx reactions in Open Loop:
for SO2

SO2 + H2O  H2SO3

Scrubber
unit
H2SO3  H+ + HSO3-

HSO3-  H+ + SO32-
PAH Sea
pH Water
SO3 2- + 0.5 O2  SO42-
Tur. inlet

PAH for SO3

Exhaust gas Residence tank
pH
Tur. inlet
SO3 + H2O  H2SO4
Settling
tank
Cleaning H2SO4 + H2O  HSO4 - + H3O+
Wash unit
Water
outlet HSO4 -+ H2O  SO42- + H3O+
 Exhaust emission in open loop mode
40 9
Scrubber unit No: 1 Scrubber unit No: 2
8 40
* CO2
* CO2
6 20 6

SO 2 [ppm]
CO 2 [%]

SO 2 [ppm]
CO2 [%]
20

4
0 3
0
2
Faulty SO2 indications * SO2 * SO2
Faulty SO2 indications
0 -20 0 -20
15-Jul 4-Aug 24-Aug 13-Sep 15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep 25-Jul 14-Aug 3-Sep 23-Sep

10 8 40

Scrubber unit No: 3 60 7

Scrubber unit No: 4
8 * CO2
6
* CO2
40 20
5
SO 2 [ppm]

CO2 [ppm]

SO 2 [ppm]
6
CO2 [%]

4
20
4 3
0

2
2 0
Faulty SO2 indications
* SO2
1
* SO2
0 -20 0 -20
15-Jul 4-Aug 24-Aug 13-Sep 15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep 25-Jul 14-Aug 3-Sep
 Sea and washwater parameters in open loop mode
10 8.0

8 pH: 7.9 pH: 6.2

6.0
pH [-]

pH [-]
6 6000 4000

5000
3000 Washwater outlet

Observations
Observations

4000
Sea Water inlet 4.0
3000 2000
4 2000
1000
1000

0 0
5.90 7.02 8.14 5.800 6.175 6.550 6.925 7.300
2 2.0
15-Jul 4-Aug 24-Aug 13-Sep 15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep 25-Jul 14-Aug 3-Sep 23-Sep

10000
40
8000 Sea Water inlet
Observations

6000

30 4000
PAH [µg/L]

2000

0
EGCS Starting up
0.1 9.1 18.1 27.0
20

10

PAH: 2.2
0
15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep
 Sea and washwater parameters in open loop mode

160 120
10000 10000
140 8000
Sea Water inlet 100 8000
Observations

120

Observations
6000 6000
Turbidity [NTU]

Turbidity [NTU]
4000 80 Washwater
100 4000
2000 outlet
2000
80 60
0
4 48 92 136 0
60 EGCS Starting up 6.00 29.75 53.50 77.25
40
40
20 20
Turbidity: 8.9
Turbidity: 6.2
0 0
15-Jul 4-Aug 24-Aug 13-Sep 15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep 25-Jul 14-Aug 3-Sep 23-Sep
 EGCS in closed loop mode - compliance monitoring

SOx reactions in Closed Loop:

Exhaust gas
outlet
SO2
CO2 for SO2
De-plume Na+ + OH- + SO2  NaHSO3
unit
2Na+ + 2OH- + SO2 Na2SO3 + H2O

Scrubber 2Na+ + 2OH- + SO2 + 1/2 O2 Na2SO4 + H2O

unit

for SO3
SO3 + H2O  H2SO4

2NaOH + H2SO4  Na2SO4 + 2H2O

Sea
Water
Exhaust gas Process tank
inlet
inlet
NaOH
tank
Holding
tank Separator
Sea Water Sludge
PAH PAH
outlet tank
pH pH
Tur. Tur.
 Exhaust emission and sea water parameters in closed loop mode

150
15
5000 1200
Rated power 100
1000

Observations
800 12
4000 50
Engine power [kW]

At berth 600

SO 2 [ppm]
0
9

CO2 [%]
400
3000 Faulty SO2

1221
Engine 200
indications -50

2000 power: 1220 kW 0 6

-100

3 -150
1000
* CO2 * SO2
-200
0
0
15-Jul 4-Aug 24-Aug 13-Sep 15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep 25-Jul 14-Aug 3-Sep 23-Sep

10.0 100

9
Sea Water outlet
8.0 80
pH: 6.9

Turbidity [NTU]
pH: 6.3
6.0 6 60
2000
pH [-]

pH [-]

1500

4.0
Observations

40
1000
Process Water * pH
inlet 3 * Turbidity
500
2.0 20
0
Turbidity: 11.8
5.2 6.2 7.2 8.2 9.2

0.0 0 0
15-Jul 4-Aug 24-Aug 13-Sep 15-Jul 4-Aug 24-Aug 13-Sep
25-Jul 14-Aug 3-Sep 23-Sep 25-Jul 14-Aug 3-Sep 23-Sep
Conclusions

1. Hybrid EGCS performance measurements were carried out on board the ship during
two month service operation period.
2. On average EGCS operation in open loop mode was 17 hrs at sea and 7 hrs a day in
closed loop at port.
3. SOX and CO2 emissions results are characterized by strong scattering of values, which
in principle makes it impossible to assess compliance with the relevant limits,
expressed in MEPC.184 (59) 2009 guidelines.
4. Undoubtedly, this has to do with variable EGCS mode of operation, which is
determined by the load of propulsion engines.
5. Sea water system exhibits much more stable parameters, qualifying for compliance
assessment. Results of measurement of seawater parameters showed a slight lower
pH value; 6.2 (OL) and 6.3 (CL) below the limit value 6.5.
6. No Turbidity of 8.9 NTU (OP) and 11.8 NTU (CL) over 25 NTU limit was exceeded.

Survey period July August

EGCS mode of operation Open Loop Closed Loop Open Loop Closed Loop
EGCS runing hours [hr] 532 212 516 228
EGCS electric consumption [kWh] 397 810 78 591 385 844 84 513
EGCS fuel oil consumption [mt] 104.1 26.8 102.9 26.2
Total ship’s fuel oil consumption [mt] 1040 988
NaOH solution consumption [ltrs] 6900 6875
 Conclusions

1. The EGCS and related facilities introduce significant increases in electricity consumption, both:
at sea and berth and this transfers into an increase in fuel consumption of 12.85 % of the total
actual ship’s flowrate.
𝐸 𝑖𝑛𝑙𝑒𝑡 𝑜𝑢𝑡𝑙𝑒𝑡
𝑆𝑂2 − 𝐸 𝑆𝑂2
2. The EGCS efficiency was estimated using the formula: 𝜉1 = ∙ 100%
𝐸 𝑖𝑛𝑙𝑒𝑡
𝑆𝑂2
and reached: 93.8 %.
3. Actual consumption of NaOH solution remains at 6.8 ltr/t of fuel oil.
4. The SOx emission for a ship equipped with EGCS was estimated at 0.47 g/kWh.

120 2.00
3000
SO2 specific emission [g/kWh]
2500
100
Scrubber efficiency [%]

2000
1.50

Observations
1500
80

SO 2 [g/kWh]
6000 1000

5000 500

60
SO2 emission - outlet [ppm] Scrubber unit 1.00 0
4000
efficiency: 93.8% -0.1650 1.1332 2.4313
Observations

0.4841 1.7823
3000
40 SO2 spec.: 0.47
2000
0.50
1000
20
0
1.26 43.10 84.94

0 0.00
0 1000 2000 3000 4000 0 1000 2000 3000 4000
Engine power [kW] Engine power [kW]
Thank you for your attention