Wartsila o e W Env SCR PDF
Wartsila o e W Env SCR PDF
Wartsila o e W Env SCR PDF
Figure 1: NOX emissions limits according to the Revised MARPOL Annex VI.
4.5
Global
4
Fuel sulphur content, %
3.5
2.5
1.5
ECA
1
0.5
0
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
The introduction of the global 0.5% limit is
Figure 2: Global and ECA fuel sulphur limits development according to the Revised MARPOL
made conditional on the outcome of a review
Annex VI.
to be completed by 2018. The purpose is to
assess the availability of fuel oil in accordance
with this requirement on the basis of the
global market supply and demand situation
at that time and an analysis of the trends
in those markets. Based on the outcome of
the review, the global limit of 0.5 % will be
implemented either in 2020 or 2025.
EQUIVALENCE CLAUSE
The use of measures that can be
demonstrated to be at least as effective in
terms of emissions reduction as technologies
for achieving compliance with the standards
of the Revised MARPOL Annex VI is explicitly
allowed – provided there are no negative
effects on the environment, human health,
resources etc.
3
TECHNOLOGY OVERVIEW
Engine In order to achieve compliance with both the
internal
measures IMO Tier III NOX standards and the requirements
for SOX control, a variety of solutions is
theoretically conceivable, starting with the
Low choice of fuel and fuel system, including
sulphur Scrubber
fuel conventional and more advanced tuning
concepts, the addition of particular substances
and, ultimately, aftertreatment. Switching
from liquid to gas fuel, for instance, could be
SCR a solution for dealing with both challenges
simultaneously, if combined with appropriate
measures for controlling the operation of the
engine. However, also when considering liquid
Figure 3: Possible combinations of NOX and SOX control technologies. fuels only, various options need to be taken into
account, combining the individual solutions to
control the two key pollutants:
182
RTA SOX
180
zz Low-sulphur fuel
178 zz Scrubber
176 NOX
174 Cost-opt. zz Engine-internal measures
bsfc, g/kWh
172 Standard
Delta
zz SCR
170
Low-load
168 BASIS FOR FURTHER DEVELOPMENT
166 As regards NOX emissions control, the
164 Tier II compliant status of Wärtsilä RT-flex
162 and RTA engines represents the basis for
160 further development. This status has been
0 25 50 75 100 125 achieved by using a tuning concept based
load, %
on the combination of individual measures
for minimum impact on other performance
Figure 4: Fuel consumption characteristics of various Tier II tuning variants of RT-flex engines parameters, thereby particularly exploiting the
and the corresponding RTA version (58T-D example). flexibility of the RT-flex system for realizing the
best trade-off between NOX emissions and
30 fuel consumption. This yields clearly superior
performance of RT-flex engines compared to
25 their RTA counterparts. Moreover, different
tuning variants are offered in order to allow
20
the customer to select the one best suiting his
intended operating pattern.
bsNOX, g/kWh
6
minimizing the sensitivity of the SCR and
engine combination to fuel composition: On the
one hand, the selection of catalyst type and
2 9
material must be considered essential; on the 1
other hand, the SCR unit needs to be properly
integrated with the engine for minimizing heat
losses and achieving optimum distribution
of the reductant. Finally, the deactivation of 8
the catalyst by means of deposits building 4 5
up – as well as the potential ageing of the 7
catalyst through small amounts of catalyst 3
poisons included in such deposits – must
be counteracted by applying a soot blowing
system, which is also needed to keep the 6
pressure loss of the SCR within acceptable
(1) Compressed air supply (7) Urea injector and mixing element
limits and to prevent clogging.
(2) Soot blowing system (8) Mixing duct
(3) Urea tank (9) SCR reactor with catalyst elements
SCR SYSTEM LAYOUT (4) Pump unit
The overall SCR system layout is shown (5) Dosing unit Default scope of supply consists of items:
(6) Exhaust gas from the engine (2), (4), (5), (6), (7) and (9)
schematically in Figure 6. It consists of the
following main components: A reducing agent Figure 6: Flow diagram of the SCR system.
storage tank, a reducing agent feeding and
dosing unit, the reducing agent injection
and mixing element, a reactor with catalyst
elements, a soot blowing system for keeping
the catalyst elements clean and the control
system. Figure 6 also includes indications
with respect to a default scope of supply from
Wärtsilä. However, Wärtsilä is open for all kinds
of arrangements, up to extending the offering
to complete systems if desired.
A pump unit transfers urea from the storage
tank to the dosing unit, which regulates the (1) Urea inlet (3) Drain valve (5) Overflow valve
flow of urea to the injection system based on (2) Filter (4) Pump (6) Urea to tan
the operation of the engine. The dosing unit
Figure 7: Flow diagram of the pump unit.
also controls the compressed air flow to the Excess urea returns to the storage tank
injector. The urea injector sprays reducing through an overflow line. A schematic flow
agent into the exhaust gas duct. After the diagram of the pump unit is provided in
injection of reducing agent, the exhaust gas Figure 7.
flows through the mixing duct to the reactor, The pump unit includes manual inlet and
where the catalytic reduction takes place. outlet valves, and a drain valve. A non-return
PUMP UNIT valve in the outlet line prevents back-flow
Besides delivering the reducing agent to the of urea from the dosing system. Pressure
dosing system, the pump unit also maintains gauges are installed on both the suction side
the required pressure in the urea lines. The and the discharge side of the pump. The
main component of the unit is an electrically pump unit is equipped with a control box,
driven pump, which is mounted on a frame which contains a frequency converter for
together with the necessary accessories. supplying power to the motor of the pump. An
A suction filter protects the pump and the emergency stop button for the pump unit is
downstream equipment from impurities. located in the front panel of the control box.
7
DOSING UNIT
The dosing unit controls the dosing of reducing
agent to the injection system. Figure 8 shows
a schematic flow diagram of this unit. The
components in the unit are mounted on a
module frame. In addition to the equipment
for dosing of reducing agent, the unit includes
components for compressed air regulation.
The flow of reducing agent is regulated
by an automatic control valve. A flow meter
measures the amount of reducing agent
(1) Compressed air inlet (4) Air pressure regulator (7) Flow control valve supplied to the injector. The urea circuit is
(2) Air filter (5) Urea inlet (8) Flow meter
equipped with manual inlet and outlet valves,
(3) Solenoid valve (6) Drain
a solenoid-actuated shutoff valve, a non-
Figure 8: Flow diagram of the dosing unit. return valve and a drain valve. In addition to
the equipment for dosing of reducing agent,
the unit includes components for compressed
air regulation. The compressed air line is
connected to the urea line through a solenoid
valve, which is closed during normal operation.
The solenoid valve is used for purging the
injection system of urea after a stop, and
for cooling the injection nozzle before the
urea injection is started in order to minimize
the risk of injector clogging due to thermal
decomposition of urea.
UREA INJECTION UNIT AND MIXING DUCT
(1) Static mixer (3) Injection nozzle The reducing agent is sprayed into the exhaust
(2) Injector lance (4) Mixing duct gas duct and mixed with the exhaust gas before
it enters the reactor. The urea injection is
Figure 9: Injector and mixing duct.
performed using compressed air. The urea and
the compressed air are mixed in an injection
nozzle at the end of the lance, injecting urea
solution into the exhaust gas as a fine spray.
The static mixer, located in the exhaust duct
either before or after the injection point, serves
for enhancing the mixing of the reducing agent
and the exhaust gas. After the injection of
reducing agent, the exhaust gas flow passes
through a mixing duct. The mixing duct gives
time for the urea to transform into ammonia
and mix homogeneously before it reaches the
catalyst elements. Figure 9 presents a typical
configuration for urea injection in the mixing
duct.
The layout of injector and mixing duct is
an essential part of the design of an SCR
system. Wärtsilä use in-house expertise in
Computational Fluid Dynamics (CFD) modelling
to determine e.g. correct positioning of urea
injectors and spray control to be able to provide
best-practice solutions for their 2-stroke
engines. Figure 10 presents an example of such
Figure 10: CFD simulation result of urea spray evaporation after injection point. optimized urea spray by means of CFD.
8
SCR REACTOR WITH SOOT BLOWING SYSTEM
The reactor is a steel casing containing
an adequate number of catalyst elements,
typically of the honeycomb type and arranged
in multiple layers, in order to achieve the 5 6
necessary conversion. As the exhaust gas 2 3
flows past the catalyst surface, the nitrogen
oxides react with the reducing agent. 1 4
Compressed air connections for soot
blowing are installed at each catalyst layer. The
reactor is equipped with a differential pressure
transmitter for monitoring the condition of (1) Compressed air inlet (4) Air vessel
the catalyst elements, and a temperature (2) Pressure regulator (5) Solenoid valves
(3) Air filter (6) Reactor with catalyst elements
transmitter for monitoring the exhaust gas
outlet temperature. Figure 11 shows a typical Figure 11: Flow diagram of a typical soot blowing system.
soot blowing arrangement.
CONTROL SYSTEM
The control system regulates the urea dosing
as a function of engine load and speed, to
ensure that the necessary amount of reducing
agent is always injected. It also controls the 2
compressed air supply to the injection system
and the soot blowers and involves specific
control features for specifying urea injection 1 3
during start / stop of the engine and transient
operation. Moreover, the position control of the
exhaust gas by-pass valves is embedded in
the control system in order to ensure correct
4 5 6
routing of the exhaust gas in all conditions.
If the system is in standby mode, the urea
injection is automatically activated when the 7
engine starts. The start of the urea injection (1) Control unit (5) Urea pump
is triggered by the catalyst temperature. (2) Soot blowing valves (6) Urea dosing control valves
Correspondingly, when the engine stops, the (3) Compressed air control valves (7) Engine
(4) Urea tank
urea dosing is shut off. The injection system is
automatically purged of urea after a stop. Figure 12: Control system layout.
9
Figure 13: Pre-turbine SCR installation on Wärtsilä 7RT-flex40 engine.
INSTALLATION DIMENSIONS
INDICATIVE SCR SYSTEM MAIN DIMENSIONS FOR SELECTED WÄRTSILÄ 2-STROKE ENGINES The main challenge with two-stroke marine
Power SCR reactor SCR reactor Mixing duct Mixing pipe installations is related to the need for
Engine kW @100% diameter length diameter length
MCR (a) mm (b) mm (c) mm (d) mm integration of the SCR between exhaust
6RT-flex50D 10 470 1900 4200 900 4700 manifold and the turbocharger, including a
7RT-flex58T 15 820 2200 4000 1100 5200 bypass for start-up, shut-down and non-ECA
8RT-flex68D 25 040 2700 4800 1400 6100 operation. As an example, Figure 13 shows a
7RT-flex82T 31 640 3000 5000 1700 6600 3-D view of the Wärtsilä SCR design on a
7RT-flex40 engine.
Such initial designs have been prepared
for various engine types and sizes. Figure 14
shows typical SCR arrangements with one and
two turbochargers and includes a table listing
preliminary SCR and mixing duct dimensions
for IMO Tier III compliant designs, to assist in
layout studies.
10
WÄRTSILÄ EXPERIENCE AND
5 REFERENCES
0 Wärtsilä has a long and wide experience on
10.000 20.000 30.000 40.000 50.000 60.000 SCRs with a total of about 400 SCR systems
Engine power, kW installed in a large variety of applications:
zz Diesel, gas and dual fuel engines
Figure 15: SCR budgetary price, €/kW. zz Marine and stationary applications
zz New-building and retrofit applications
INSTALLATION COSTS requires an air compressor and a tank for zz 4- and 2-stroke engine applications.
The Wärtsilä SCR delivery scope can vary storing the reducing agent. Wärtsilä’s scope First references on 2-stroke engines date
depending on the needs and preferences of the can be extended to cover these items, or back to 1999/2000, when three RoRo ships
client. In the determination of the equipment Wärtsilä can assist through specifications or were equipped with SCR systems. Each ship
costs as shown in Figure 15, it is assumed instructions. has one main engine (Sulzer 7RTA52U) and
that the default delivery covers the following two auxiliary engines (Wärtsilä 6L20). These
equipment: OPERATING COSTS installations have received a certificate for low
zz a reactor housing with catalyst elements Urea costs are the dominating factor in the NOX emissions (< 2 g/kWh), already realizing
zz equipment for injection and mixing of total O&M costs, depending on the urea NOX emission reductions even beyond Tier III
reducing agent market price. The average consumption of requirements.
zz a unit for dosing of reducing agent urea for reaching the IMO Tier NOX level is The demand for SCR systems is expected
zz a pump unit for transfer of reducing agent approximately 15 l/MWh. If one assumes 40% to progressively increase in marine applications
zz a soot blowing system urea solution price variation between 0.30 and in 2016, and the ultimate products will be
zz a control and automation system (Control 0.60 €/l, this will result in a typical operating ready to match the current requirements.
cabinet with PLC) cost of 4.5 to 9 €/MWh. Wärtsilä already offers and delivers SCR
The scope of supply excludes e.g. piping, systems for high sulphur applications, and is
exhaust gas by-pass valves, support SCR SYSTEM CERTIFICATION making big efforts for further development
structures, flexible hoses, insulation material The certification of engines equipped with and commercialization of SCRs, in close co-
and any other parts outside the specified Wärtsilä SCR systems is done in accordance operation with engine development. The clear
scope. The operation of the system also with guidelines approved by the IMO at the emphasis is on minimizing total lifecycle costs.
11
05.2011 / Bock´s Office / Litoset
Wärtsilä is a global leader in complete lifecycle power solutions for the
marine and energy markets. By emphasising technological innovation
and total efficiency, Wärtsilä maximises the environmental and economic
performance of the vessels and power plants of its customers. Wärtsilä
is listed on the NASDAQ OMX Helsinki, Finland.