Emission control of medium speed engines in marine and power plant use

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2 Emission control of medium speed engines in marine and power plant use EEN-E2007 Energy, Environment and Emission Control Satu Korhonen, Wärtsilä 2 Wärtsilä PUBLIC

3 Satu Korhonen Product Manager, CSO, Catalyst Systems, Environmental Solutions, Marine Solutions, Wärtsilä Finland Catalyst Systems is end-to-end responsible for emission control products CSO (land based) and NOR (marine) Career in Wärtsilä: 06/2016 Present, Product manager, CSO 01/ /2016, Senior Catalyst Expert 01/ /2014, Technology Specialist for emission control systems Career outside Wärtsilä: 09/ /2010, Post doctoral fellow, Utrecht University, The Netherlands 01/ /2008, Research scientist, postgraduate student, Helsinki University of Technology, Laboratory of Industrial Chemistry 11/2008, D.Sc.(Tech) Industrial Chemistry, Helsinki University of Technology Contact: 3 Wärtsilä PUBLIC

4 CONTENT This is Wärtsilä Wärtsilä engines and emissions in short Emission limits: marine and landbased applications Catalytic emission control: What is catalysis? What is SCR? What is oxidation? Wärtsilä NOR and CSO products SOx emissions and control 4 Wärtsilä PUBLIC 11/27/2017

5 THIS IS WÄRTSILÄ Our business areas SERVICES ENERGY SOLUTIONS MARINE SOLUTIONS 5 Wärtsilä PUBLIC 27 November 2017

6 THIS IS WÄRTSILÄ What we bring to the market EFFICIENCY ENVIRONMENTAL SOLUTIONS FUEL FLEXIBILITY 6 Wärtsilä PUBLIC 27 November 2017

7 THIS IS WÄRTSILÄ A Comprehensive product portfolio AUTOMATION BALLAST WATER MGMT ENERGY STORAGE ENGINES & GENERATING SETS EXHAUST GAS CLEANING LIFECYCLE SOLUTIONS GAS SYSTEMS INERT GAS SYSTEMS NAVIGATION POWER ELECTRIC SYSTEMS INCL. WÄRTSILÄ GENIUS SERVICES PROPULSORS & GEARS PUMPS & VALVES SEALS, BEARINGS & STERN TUBES SHIP DESIGN SOLAR THRUSTERS WASTE, OIL & FRESH WATER MGMT 7 Wärtsilä PUBLIC 27 November 2017

8 THIS IS WÄRTSILÄ Production and services globally Services network Production facilities (fully owned) Production facilities (joint ventures) 8 Wärtsilä PUBLIC 27 November 2017

9 THIS IS WÄRTSILÄ Our personnel Approximately 18,000 professionals In over 200 locations In more than 70 countries 9 Wärtsilä 27 November 2017

10 THIS IS WÄRTSILÄ Our nationalities Finland India Italy Germany Netherlands China Norway Great Britain U.S. Brazil France Pakistan Poland Singapore Philippines Spain South Korea Denmark Bangladesh Canada Russia Indonesia Japan Sweden Kenya Ecuador Turkey Greece Myanmar Malaysia Switzerland Nigeria Senegal Dominica Colombia Lithuania Hungary Argentina South Africa Mexico Saudi Arabia Guinea Sri Lanka Cameroon Australia Zambia Estonia Romania Azerbaijan Puerto Rico Madagascar Portugal Taiwan Guyana Mauritania Jordania Panama Peru Pap.New Guinea Gabon Macau Chile Oman Tanzania Vietnam Venezuela Iran Cyprus Guatemala Nepal Ukraine Dominican East Timor Cuba Croatia Republic Uruguay Netherlands Bulgaria Egypt El Salvador Serbia Ireland Jamaica Mozambique Antilles Slovenia Albania Ghana Latvia Morocco Somalia Uganda Antigua Austria Belgium Burkina-Faso DR Congo Falkland Islands Mauritius New Zealand Surinam Syria Togo Thailand United Arab Emirates Afghanistan Anguilla Armenia Angola Belize Australia Congo Christmas Island Czech Republic Eritrea Ethiopia Faroe Islands Honduras Haiti Israel Iraq Iceland Cambodia Kazakhstan Lebanon Namibia North Korea Niger Paraguay Rwanda Sudan Slovakia Tunisia Yugoslavia 10 Wärtsilä PUBLIC 27 November 2017

11 THIS IS WÄRTSILÄ Our key growth areas are defined around global megatrends ENERGY EFFICIENT SOLUTIONS GAS BASED TECHNOLOGY INNOVATIVE SOLUTIONS Smart Power Generation combining energy efficiency, fuel and operational flexibility Most complete offering of marine products and integrated solutions, including a broad portfolio of environmental products Hybrid power generation and global systems integration enable optimised asset performance over the lifecycle A forerunner in gas and multi-fuel engines, fuel systems, technology and services Offering that covers gas value chain from exploration to end consumers Wide LNG offering in small and midsized terminals Making use of digital technology in lifecycle solutions to optimise the operations of our customers Building on E&A, engineering competence and digitalisation to offer hybrid solutions and new business models Strong and global track record in distributed energy project management 11 Wärtsilä PUBLIC 27 November 2017

12 SERVICES We create lifecycle services with our customers, enhancing their businesses whenever, wherever 12 Wärtsilä PUBLIC 27 November 2017

13 SERVICES Our Services business is unrivalled in the market Optimising customer operations whenever, wherever is our shared passion. Our expertise and wide offering of services are developed to meet the needs of our customers according to their business objectives and match with environmental requirements. Proprietary global network consisting of 11,000 service professionals, and advanced technology competences Our advanced technology and installed base is a key driver for growth Extensive offering designed with a lifecycle perspective and beyond Wärtsilä s installed base Digitalisation: business understanding & customer legacy combined with digital offering and virtual & mobile solutions 13 Wärtsilä PUBLIC 27 November 2017

14 ENERGY SOLUTIONS We are a leading global systems integrator offering a broad range of environmentally sound solutions. Our flexible and efficient solutions provide superior value to customers and enable a transition to a more sustainable and modern energy system. 14 Wärtsilä PUBLIC 27 November 2017

15 ENERGY SOLUTIONS Offering Flexible baseload power plants Capacity for grid stability, peaking and load-following generation, and back-up power for integrating wind and solar energy Multi-fuel solutions enabling use of any gas or liquid fuels Utility-scale solar PV power plants and solar-engine hybrid solutions Energy system integration capabilities Small and medium scale LNG liquefaction plants, LNG terminals and distribution systems Project development and EPC capability 15 Wärtsilä PUBLIC 27 November 2017

16 MARINE SOLUTIONS We are the leading provider of innovative products and integrated solutions in the marine and oil & gas industries. As a leader in our fields, we need to continuously develop and transform ourselves to meet changing customer needs. We have a passion to do right for our customers and the environment. 16 Wärtsilä PUBLIC 27 November 2017

17 MARINE SOLUTIONS THE MOST COMPLETE MARINE OFFERING ON EARTH 17 Wärtsilä PUBLIC 27 November 2017

18 Catalysts Systems End-to-end responsibility for emission control products CSO (land based) and NOR (marine) R&D Sales Product management Engineering Delivery Applications (commissioning, warranty site support etc.) In total ~30 people in Helsinki, Turku & Vaasa 18 Wärtsilä PUBLIC 11/27/2017

19 REFERENCES Wärtsilä catalyst deliveries since 1990s Gas fuel power plants with very low emissions in USA World s first cruise ship with SCR for high Sulphur and high ash heavy fuel oil 19 Wärtsilä PUBLIC

20 CONTENT This is Wärtsilä Wärtsilä engines and emissions in short Emission limits: marine and landbased applications Catalytic emission control: What is catalysis? What is SCR? What is oxidation? Wärtsilä NOR and CSO products SOx emissions and control 20 Wärtsilä PUBLIC 11/27/2017

21 Wärtsilä engine technologies SPARK-IGNITION GAS (SG) DIESEL ENGINE ** ** ** ** ** * ** * * GAS INJECTION DUAL-FUEL (DF) ** ** ** ** * * GAS INJECTION - Otto process in GAS mode: Gas fuel is ignited by pilot LFO - Diesel process in liquid fuel mode - Change from gas to LFO possible at all loads. LFO to gas at loads below 80% Wärtsilä PUBLIC 11/27/2017

22 SOx emissions Formed from the sulphur contained in raw materials such as coal and oil during combustion and refining processes SO 2 dissolves in water vapour in the air to form acids Acid rain destroys crops, buildings, freshwater lakes and entire ecosystems Harmful to both people and the environment 22 Wärtsilä PUBLIC

23 NOx emissions NOx emissions: NO + NO 2 Formation is thermal, main source is N 2 in combustion air Environmental impacts: acid rain, eutrophication, smog Harmful to both people and the environment 23 Wärtsilä PUBLIC 11/27/2017

24 CO and VOC emissions Formed during uncomplete combustion High combustion temperatures and good mixing of fuel and combustion air help minimize emissions CO is toxic to hemoglibic animals VOC (volatile organic carbon) is a range of hydrocarbons. These cause smog together with NOx and can be carsinogenic (e.g. Formaldehyde) 24 Wärtsilä PUBLIC 11/27/2017

25 NOx Formation in the Diesel Process During injection (after ignition): Fully developed turbulent diffusion flame The flame plume is like a growing balloon Highest NOx formation at the flame front Rich premixed Combustion zone λ ~ 1 Air entrainment Reaction products, NO Wärtsilä PUBLIC

26 Why Lean Burn Gas Engines Typical Influence of Air-to-Fuel Ratio Engine power (kw) Air - fuel ratio Engine Knocking 1 Lean Burn > 2 Engine misfiring Thermal efficiency (%) NOx (g/kwh) THC/CH4 emissions (g/kwh) GWG index as CO 2 Equivalents (g/kwh) Wärtsilä PUBLIC

27 Emissions summary Emission values [%] NOx emissions: Diesel engine >> Gas mode DF > SG HC/VOC and CO emissions: Gas mode DF ~ SG >> Diesel engine SOx emissios are fuel dependent, liquid fuels tend to have higher S content than gas PM emissions higher in liquid fuel operation than with gas CO 2 NO x SO x Particulates Dual-Fuel engine in gas mode Diesel engine Wärtsilä PUBLIC

28 CONTENT This is Wärtsilä Wärtsilä engines and emissions in short Emission limits: marine and landbased applications Catalytic emission control: What is catalysis? What is SCR? What is oxidation? Wärtsilä NOR and CSO products SOx emissions and control 28 Wärtsilä PUBLIC 11/27/2017

29 MARINE APPLICATIONS Marine environmental regulations have taken a step forward North Europe ECA Max 1.0% SO x in fuel 0.1% SO x in EU ports North America ECA 1.0% SO x Global cap 3.5% SO x All ECA 0.1% SO x Inert Gas System mandatory for newbuild tankers above 8,000 DWT as of 1 January 2018 Global cap 0.5% SO x NO x Tier II (Global) NO x Tier III in NECA (North America) NOx Tier III North Europe NECA US Ballast Water Management Convention Global Ballast Water Management Convention IMO MEPC. 159(55) USA EPA VGP Grey water Alaska GP2013 IMO MEPC.227(64) IMO Polar Code SO x legislation: Current cost of low sulphur fuels have reduced the pressure to consider alternative solutions LNG gaining popularity NO x legislation: North American waters affected from , Northern Europe from NO x reducing techniques such as selective catalytic reduction (SCR) or exhaust gas recirculation (EGR) are needed Ballast Water Convention: The Convention will enter into force on 8 September 2017 Applies for all vessels above 400GT in operation and newbuild Black and grey water: Regulations being developed locally Non-discharge zones and port facilities compete with onboard cleaning EU Inland water ways 2013 Black and grey water 29 Wärtsilä PUBLIC 27 November 2017

30 MARINE APPLICATIONS NOx limits NO X (g/kwh) Wärtsilä NOR operation area Primary methods operation area Secondary methods operation area Tier I >130 kw New ships 2000 Tier II >130 kw New ships 2011 Tier III >130 kw New ships from 2016 When operating inside Emission Control Areas (ECA) Rated engine speed (rpm) 30 Wärtsilä PUBLIC

31 Emission limits in landbased installations Country, state or even region/area dependent. Single digit NOx emission limits in US Emission limits may be dependent on fuel type and power plant operation mode Limited components (some examples): NOx CO Formaldehyde VOCs NH3 SOx PM 31 Wärtsilä PUBLIC 11/27/2017

32 CONTENT This is Wärtsilä Wärtsilä engines and emissions in short Emission limits: marine and landbased applications Catalytic emission control: What is catalysis? What is SCR? What is oxidation? Wärtsilä NOR and CSO products SOx emissions and control 32 Wärtsilä PUBLIC 11/27/2017

33 What is catalysis? Catalyst: Participates in reaction but is not itself consumed by the reaction Provides an energetically favorable pathway for the reaction May affect the selectivity B A Image from Wikipedia With catalyst C 33 Wärtsilä PUBLIC

34 SCR = Selective Catalytic Reduction Selective catalytic reduction requires Reducing agent: NH3 (urea) Catalyst with a high surface area and low back pressure: monoliths Temperature Oxygen Provided by the exhaust Urea water solutions typically used as reducing agent Urea decomposes into NH 3 at high temperatures Urea solutions are easier to store than NH 3 (g) NH 3 is also toxic Decomposition of urea into ammonia: H 2 NCONH 2 + H 2 O 2NH 3 + CO 2 34 Wärtsilä PUBLIC

35 WHAT IS SCR? SCR = Selective Catalytic Reduction Reducing agent injection Evaporation, decomposition and mixing SCR reaction Reducing agent is injected into exhaust duct. Urea is decomposed into ammonia (NH 3 ), CO 2 and H 2 O Ammonia will react with NOx to form N 2. NOx NH 3 SCR N 2 H 2 O O 2 FLOW DIRECTION 35 Wärtsilä PUBLIC

36 Oxidation catalysts Oxidation catalysts are used for e.g. CO and VOC abatement Catalysts contain noble metal(s) No reagents needed, no waste produced Substrate Wash coat Flue gas CO O 2 Active material CH 2 O O2 CO 2 + H 2 O For moderate oxidation requirements a simple catalyst disc that is inserted into exhaust duct bellow may be enough 36 Wärtsilä PUBLIC

37 CONTENT This is Wärtsilä Wärtsilä engines and emissions in short Emission limits: marine and landbased applications Catalytic emission control: What is catalysis? What is SCR? What is oxidation? Wärtsilä NOR and CSO products SOx emissions and control 37 Wärtsilä PUBLIC 11/27/2017

38 WHAT IS SCR? SCR = Selective Catalytic Reduction Reducing agent injection Evaportation, decomposition and mixing SCR reaction Reducing agent is injected into exhaust duct. Urea is decomposed into ammonia (NH 3 ), CO 2 and H 2 O Ammonia will react with NOx to form N 2. NOx NH 3 SCR N 2 H 2 O O 2 FLOW DIRECTION 38 Wärtsilä PUBLIC

39 WÄRTSILÄ SCR PRODUCTS FOR MARINE AND LAND BASED APPLICATIONS Silencer CSO reactor Mixing duct with urea injection Absorptive silencers and scrubber after SCR Boilers and other equipment after SCR Scrubber Boiler Dosing unit NOR Mixing & Injection unit Compact NOR with integrated SCR reactor and silencer Reactive silencers Mixing silencer including injection unit Urea tank Urea pump MARINE LAND BASED 39 Wärtsilä PUBLIC

40 OVERVIEW OF NOR AND CSO PRODUCTS Product name Marine NOR (NOx Reducer) Land based CSO (Combined SCR and Oxi) Primary technology SCR SCR + oxidation Reductant Urea solution Urea or ammonia solution Emission compliance IMO Tier III Other regulations e.g. Norwegian NOx Fund US, IED limits Tailor made solutions Released solutions available for Fuel Wärtsilä diesel and DF engines in diesel mode All distillate fuels (LFO and HFO) and gas Wärtsilä gas engines, Wärtsilä diesel and DF engines in gas and diesel mode Mainly gas and low sulphur liquid fuel. Also HFO plants without oxidation catalyst. 40 Wärtsilä PUBLIC

41 WÄRTSILÄ STANDARD SCOPE OF SUPPLY FOR CSO Reactor housing Catalyst elements (Automatic soot blowing unit) Complete mixing duct with urea injector Reducing agent dosing unit Control and automation unit Reducing agent pump unit NOx analyzers Typical customer scope: Reducing agent tank Piping and insulation Compressed air supply Catalysts Reactor Common units Control unit Pump unit Complete mixing duct with injector Dosing unit NOx analyzer 41 Wärtsilä PUBLIC

42 120 Transient operation with gas engines demands on control system Load (%) Low NOx, CO and VOC 0 Stable emission level Fast, reliable and accurate emission measurement and feedback control 20 12:00:00 13:00:00 14:00:00 15:00:00 Fast and accurate regent dosing transient operation conventional stable operation Dynamic engine operation: variable temperature, flow and emission level Reagent injection 42 Reagent pump Wärtsilä PUBLIC

43 Example of NOx emissions at changing conditions Engine NOx emissions Load and ppm :00:00 14:30:00 15:00:00 15:30:00 16:00:00 16:30:00 Engine Nox (15% O2, dry) Load Stack NOx emissions after Wärtsilä CSO ppm :00:00 14:30:00 15:00:00 15:30:00 16:00:00 16:30:00 15 min AVG Nox ppm (stack), 15 % O2, dry Load Engine load 43 Wärtsilä PUBLIC

44 CONTENT This is Wärtsilä Wärtsilä engines and emissions in short Emission limits: marine and landbased applications Catalytic emission control: What is catalysis? What is SCR? What is oxidation? Wärtsilä NOR and CSO products SOx emissions and control 44 Wärtsilä PUBLIC 11/27/2017

45 ALTERNATIVES TO REDUCING SOX FUEL SWITCH Switch to low sulphur fuel in SECA. Only reasonable until 2020? PROS Flexible Small investment CONS High operating cost in SECA Fuel change over procedures Lube oil TBN management Fuel availability? CHANGE TO MGO Run full time on Marine Gas Oil (MGO). Convenient No change over High operating cost Future availability? CONVERT TO LNG Convert engines to run on gas (LNG). A solution which also reduces NO x and particulates Investment cost LNG availability USE SCRUBBERS Install an exhaust gas cleaning system (scrubber). Works with high S HFO Lowest total lifecycle cost Use everywhere Easy operation ROI depends on fuel oil price difference between low S fuel oil and high S HFO 45 Wärtsilä PUBLIC

46 Wärtsilä main scrubber portfolio Open loop scrubber sea water operations Uses seawater i.e. no freshwater needs Slightly higher power demand than FWS Does not need caustic soda Applications: main alternative for ocean-going ships Closed loop scrubber fresh water/closed loop operations Independent on seawater alkalinity Zero effluent discharge an option Low power demand Needs caustic soda as a reagent Applications: seas with extremely low alkalinity and for operators looking for continues closed loop operation Hybrid scrubbers open loop / closed loop operations Flexible system More complex system Applications: ships requiring full flexibility of operations 46 Wärtsilä PUBLIC

47 OPEN LOOP SCRUBBER VIDEO 47 Wärtsilä PUBLIC

48 THANK YOU!