1 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014 CIMAC NMA Norge Norwegian Shipowners' Association, 22nd January 2014, Low speed Tier III technologies EGR, SCR and combined EGR and EGC scrubber Kjeld Aabo Director Customer support Marine Low Speed Disclaimer All data provided on the following slides is for information purposes only, explicitly non-binding and subject to changes without further notice.
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1 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
CIMAC NMA Norge
Norwegian Shipowners' Association, 22nd January 2014,
Low speed Tier III technologies
EGR, SCR and combined
EGR and EGC scrubber
Kjeld Aabo Director
Customer support
Marine Low Speed Disclaimer
All data provided on the following slides is for information purposes only,
explicitly non-binding and subject to changes without further notice.
2 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Two-stroke Low Speed Engines Marine Engines
3 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
1 EGR – Exhaust Gas Recirculation
2 SCR – Selective Catalytic Reduction
3 Combined EGR and EGC (Exhaust Gas Cleaning) scrubber
Low speed Tier III technologies
4 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014 3336719.2010.04.27 (NK/LDF)
EGR
(Exhaust
Gas Recirculation)
SCR
(Selective
Catalytic Reduction)
Low speed Tier III technologies
5 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014 3336719.2010.04.27 (NK/LDF)
EGR
(Exhaust
Gas Recirculation)
EGR combined with EGC scrubber
EGC scrubber
(Exhaust
Gas Cleaning scrubber)
Combined
SOx reduktion NOx reduktion
6 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
1 EGR – Exhaust Gas Recirculation
2 SCR – Selective Catalytic Reduction
3 Combined EGR and EGC (Exhaust Gas Cleaning) scrubber
Low speed Tier III technologies
7 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR
System layout med T/C cut-out matching
8 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR System Layout with cylinder bypass
matching
9 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Auxiliary system for EGR
10 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR integrated engine design:
6S80ME-C9.2
EGR inlet pipe &
pre-scrubber
Dual cooler
EGR scrubber
EGR blower
Distribution chamber
Mixing chamber
EGR outlet pipe
11 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR Unit Integrated on Engine
EGR inlet pipe &
pre-scrubber (not seen)
EGR cooler
EGR scrubber
EGR blower
Distribution chamber
Water Mist Catcher
EGR mixing
12 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
New EGR Unit Design
Compact EGR unit designed
for engine-mounting
Combined scrubber/cooler to
optimise scrubbing and
lowering the scrubber water
temperature
Water mist catching after
scrubber by reversing
chamber and high efficiency
WMC
Coolers
Scrubbers
WMC
Outlet
Inlet Pre-conditioned
EGR gas
Reversing
chamber
13 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR key components
EGR cooler EGR blower
Valves EGR sensor
EGR unit
On engine Off engine
Water Treatment System
Scrubber Control system
Tanks
Drain
14 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR control system - HMI
15 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
NOx certification of EGR engine modes
for TC Cut-out engine
IMO NOx certifi-
cation (Test cycle E2 or E3)
Tier II
(Cycle value calculated from highest NOx value
from each load point)
Tier III
Engine mode Economy No EGR Low EGR* High EGR
Engine mode no. 1 2 3 4
Turbochargers in
operation
Basis+ Cut-
out TC Basis TC Basis TC Basis TC
Load range 0 - 110% 0 – 50% 0 - 75% 0 - 100%
* Optional if test bed results are positive
16 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Shop test of 6S80ME-C9.2 at HHI-EMD,
September 2012
Tier III NOx levels: cycle value & mode caps
Fuel optimised Tier II EGR mode concept
EGR engine Control & Safety system
High efficient EGR scrubber
EGR blowers
EGR oxygene sensor setup
EGR coolers
EGR Water Treatment System
17 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Expected change in fuel oil consumption
ECA-EGR
Tier III
Low EGR
Tier II
Economy
Tier II
100% +4 +4 0
75% +3 +0 0
50% +2 -5 0
25% +0 -5 0
ECA-EGR
Tier III
Low EGR
Tier II
Economy
Tier II
100% +5 +3 +2
75% +4 -1 0
50% +3 -5 -5
25% +0 -5 -5
EGR engine with cut-out turbocharger:
EGR engine with cylinder by-pass:
*For some engines it is nessecary to remove shims in order to
avoid smoke in ECA-EGR mode which can result in a higher SFOC in
Low EGR mode.
18 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
NOX and PM in exhaust – test results
: Economy mode
: Low EGR mode
: ECA-EGR mode
19 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR engine parameters
: Economy mode
: Low EGR mode
: ECA-EGR mode
20 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
6S80ME-C9-EGR on-board Maersk Cardiff
21 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR Service test status
Alexander Maersk – EGR launched March 2010
>2400 running hours on HFO with 3% sulfur
Engine components is not affected by EGR
Crew operates the system
Maersk Cardiff – EGR launced February 2013
>1000 running hours on HFO with 3% sulfur
Engine components is not affected by EGR
EGR system components works well
Crew operates the system
22 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
EGR references (service tests)
13.09.2013 RASA/ Dept LSP
In service –
Launched in march
2010
In service –
Launched in march
2013
Ordered –
Delivery in June and
Sept. 2013
Ordered –
Delivery in
Dec. 2014
23 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Installation aspects
24 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Conclusions on EGR development
Compact EGR engine design for 6S80ME
and 6G70ME engine is completed.
Tier III test results with satisfying SFOC and
other emissions are confirmed.
Service test of EGR is progressing as
planned.
EGR concepts for entire engine program is
identified and validated.
Commercial orders is signed with Chevron
and NYK.
25 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
1 EGR – Exhaust Gas Recirculation
2 SCR – Selective Catalytic Reduction
3 Combined EGR and EGC (Exhaust Gas Cleaning) scrubber
Low speed Tier III technologies
26 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
SCR
System layout på motor
V2
V1
V3
V4
27 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
System layout Demonstration of solutions
Increase of exhaust gas temperature
SCR system placed on the high pressure side of the turbine
28 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
System layout Demonstration of solutions
Increase exhaust gas temperatures further at low load
Cylinder & SCR bypass provide correct temperature
Example: Temperature must be increased 70°C from 260°C to 330°C at 25%
29 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
System layout Demonstration of solutions
Integrate the temperature control in the Engine Control System
Departure from harbor
Maneuvering, accelerations and deceleration
Low speed
30 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Tier III SCR System
31 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Tier II operation
– The exhaust gas goes
directly to the turbine
Tier III SCR System
32 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Tier III SCR System Pre-turbine SCR
Tier III operation
– The exhaust gas is
directed to the SCR
reactor
33 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
Auxiliary system for SCR
3338581.2013.01.25
34 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014
System layout Demonstration of solutions
Integrate the temperature control in the Engine Control System
Departure from harbor
Maneuvering, accelerations and deceleration
Low speed
35 < > MAN Diesel & Turbo CIMAC seminar, Norway, 22. January 2014