pm/bc reduction by dpf and wet-esp for marine ship engines ... reduction by dpf and wet... · pm/bc...
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PM/BC Reduction by DPF and wet-ESPfor marine ship engines:
Recent R&D in Korea
Sunho Park
Sep. 19th, 2018ICCT’s 5th Workshop on Marine Black Carbon Emissions
Associate ProfessorDepartment of Mechanical Engineering
Dankook UniversityRepublic of Korea
5th ICCT Workshop September 2018, SF
Outline
5th ICCT Workshop September 2018, SF
1. Background
Speaker’s research at Dankook UniversityVOC Removal
by Plasma
Optical Diagnostics: Soot in Flame Burner Design
Synthesis and Characterization of PMAnimal Exposure
Flame Stabilization
PM from ship(HFO)
5th ICCT Workshop September 2018, SF
1. Background
Air pollutants from ship and their climate effects
Source: Atmospheric Sciences
Why is Greenland's ice getting darker?
5th ICCT Workshop September 2018, SF
1. Background
Particulate MattersSchematic of diesel PM
Main fractions Sub-category
Solid fraction(SOL)
- Elemental carbon- Ash
Soluble organic fraction (SOF)
- Organic material derived from L.O.- Organic material derived from Fuel
Sulfate particulates(SO4)
- Sulfuric acid- Water
Total particulate matter(TPM) = SOL + SOF + SO4
[TEM image of particulate matters]
Guan, 2015, J. Environ. Management
Source : Diesel particulate filter, www.dieselnet.com
5th ICCT Workshop September 2018, SF
1. Background
‘Consideration of the impact on the Arctic of emissions of Black Carbon from international shipping’
▶ We finalized the definition for Black Carbon,▶ We have been identifying appropriate methods for measuring black carbon emissions, and
▶ We are considering possible control measures that reduce black carbon emissions from international shipping.
IMO PPR Agenda
5th ICCT Workshop September 2018, SF
1. Background: Global Projects
The objectives of the HERCULES-2• Fuel flexible engine• New materials• Adaptive power plant• Near-zero emissions engine
Work package 8• 80% PM reduction with after-treatmentsystem• Adaptation and integration of after-treatmentsystem(SCR on DPF)
Budget: 86 M€ + 25 M€Duration : 119 months + 36 months
M/V Victoria (BP)Dimension: 69.96 X 11.44 X 4.25(LBD, m)M/E: MTU8V4000, 880 kW, 1,800 rpm
DPFBurner
SCR
After-treatment systemDPF + SCR
Fuel- Low sulfur fuel
Operation- Advising speed control
Electrostatic SeaWaterScrubber(ESWS)• SOx and PM removal
Non-thermal Plasma Reactor• NOx and VOC abatement
SCR• Removal of any residual NOx
ESWS wash water treatment system• Treatment of liquid by-products
Innovative After TreatmentSystem for Marine Diesel EngineEmission Control
Budget: 3.465 M€ Duration : 3 yr. (09/2011 ~ 08/2014)
Cleanest ship project DEECON project HERCULES project
Contents NOx PM SOx
Engine out emission
8 0.15 0.81
Emission with reduction tech.
0.2-2.2 0.004 0.004
Reduction rate(%)72.5-90.0
97.3 99.5
5th ICCT Workshop September 2018, SF
1. Background
Recent government-supporting R&D in KoreaDevelopment of NOx reduction unit for
10,000 ps-class ship engines (2011~2017, Ministry of Oceans and Fisheries)
Installation and proof of SOx scrubber for ships toward IMO global sulfur cap (2018~2021, Ministry of Oceans and Fisheries)
EGCS for Tier Ⅲ regulation and 0.1%-sulfur fuel(2012~2014, Ministry of Trade, Industry and Energy)
5th ICCT Workshop September 2018, SF
2. R&D Overview
Development of DPF and wet-ESP for ships▶ 2012-2018, Ministry of Oceans and Fisheries
<2 st. diesel engineHHI-MAN B&W 6S46MC-c7>
WET EP(3 MW BC/SOxafter-treatment system)
Diesel particulate filter
400 kW marine diesel engine
Back pressure sensor
Gas analyzer
PM analyzer
<Inlet and outlet view in DPF system>
1,500 TEU container
5th ICCT Workshop September 2018, SF
2. R&D Overview
Basic Principles Wet Electro-static Precipitator
Schematic
electrode
corona dischargeelectrode
particle chargingcollectorplate
adsorption
CollectingPlate (+)
Electrode (-)
Diesel Particulate Filter
Filtered gasGas from engine outlet
Schematic
water film
water film
Regeneration necessary
Flushing of collector plate necessary
5th ICCT Workshop September 2018, SF
2. R&D Overview
Ship application characteristics and the R&D objectives▶ Ship application characteristics
- High sulfur content in fuel results in SO2 in exhaust gas and a high sulfate fraction in PM
: Sulfur poisoning of catalyst, Corrosion of ESP electrode, etc.
- PM contains more SOF (soluble organic fraction)
: Controlling regeneration of PM in DPF is harder, DOC functionality issue
- Size of the after-treatment system is much greater than the system for land vehicles
- Allowable back pressure is lower
- Ship stability issue⁞
▶ Objectives: Not only deal with the issues in the above, but also satisfy the following conditions ;
Wet Electro-static Precipitator Diesel Particulate Filter
on par with existing systems
5th ICCT Workshop September 2018, SF
2. R&D Overview
Test bench for marine engine emission and performanceLow speed engine cell High/midiumspeed engine cell
▶ Fuel : Bunker-A (0.29%S), high sulfur diesel(0.34, 0.05%S), ULSD(< 10 ppmS)▶ Engine : HHI-MAN 6S46MC(2-str., 7.4 MW), Doosan Infracore 4V158TIH(4-str., 403 kW)▶ Test cycle : E2, E3 cycle from ISO 8178
Korean Register Testing & Certification Center
Gunsan, Korea
5th ICCT Workshop September 2018, SF
2. R&D Overview
PM emission from the test engines
Tota
l PM
Emis
sion
rate
(g/h
)
Soot
E2
E2
E2
E2
E3
E3
E3
E3
<Comparision of SOF> ULSD HSDSOF Sulfate
2-st 7.4 MW engine
ULSD HSD
4-st 400 kW engine (ULSD)
5th ICCT Workshop September 2018, SF
3. DPF for 400 kW ship engine
Part design and developmentPore former and microstructure of the substrate
Parameter
Pore former
GraphitePMMA Walnut
shellA B C D
Density [g/cm3] 1.3 1.3 1.3 1.3 1.3 1.2
Porosity [%] 50.1 50.6 49.9 51.0 50.5 53.7
Ave. pore size [㎛] 6.7 6.7 6.8 7.7 8.0 10.7
Intrusion vol. [cc/g] 0.40 0.27 0.37 0.39 0.37 0.30
0 20 40 60 80 100 1200
10
20
30
40
50
60
70
Pres
sure
Dro
p(m
bar)
Air Folw Rate (kg/h)
5P 10P 15P 20P 25P 30P
Air Flow Rate vs Back Pressure
Compressive Strength vs Pore Former Cont.(%)
Air flow controller Flame controlFuel injecting nozzle Burner systemizationIgnition test
Active regeneration burner
5th ICCT Workshop September 2018, SF
3. DPF for 400 kW ship engine
Test resultsDPF system for 400 kW engine
0
0.005
0.01
0.015
0.02
3 mode 4 mode 2 mode 3 mode 4 mode
Parti
cula
te m
ass
[g/k
wh]
E2 cycle E3 cycle
Engi
ne o
ut e
mis
sion
DPF
dow
nstr
eam
0
0.005
0.01
0.015
0.02
0.6
0.8
1
1.2
1.4
3 mode 4 mode 2 mode 3 mode 4 mode
Filte
r sm
oke
num
ber [
-]
E2 cycle E3 cycle
Engi
ne o
ut e
mis
sion DP
F do
wns
tream
0
2
4
6
8
10
3 mode 4 mode 2 mode 3 mode 4 modeO
paci
ty [%
]E2 cycle E3 cycle
Engi
ne o
ut e
mis
sion
DPF
dow
nstre
am
Gravimetric OpacityFSN
Ave. reduction: 84%
Experimental conditions (E2 & E3 cycle)
Cycle E2 cycle E3 cycle
Power [kW] 403 302 202 101 403 302 202 101
Speed [rpm] 1,800 1,800 1,638 1,440 1,134
Torque [Nm] 2,139 1,604 1,069 535 2,139 1,763 1,337 849
Mode 1 2 3 4 1 2 3 4
5th ICCT Workshop September 2018, SF
4. Wet-ESP for 3MW ship engine
Background research
참조 : 최종보고서내 pp. 336-341, 별책 1 내 pp.199-235
Electrostatic precipitator
0
5
10
15
20
Mode 1 Mode 2 Mode 3 Mode 4
Soo
t con
cent
ratio
n [g
/m3 ]
E3 cycle
Engine outDownstream of ESP
0
0.5
1
1.5
2
Filte
r Sm
oke
Num
ber [
-] Engine out
E3 cycleMode 3Mode 2Mode 1 Mode 4
Downstream of ESP
100
1000
104
105
106
107
10 100 1000
Par
ticle
num
ber c
once
ntra
tion
[#/c
m3 ]
Dp [nm]
Engine outDownstream of ESP
Hydraulic dynamometer
2-ST diesel engineHHI-MAN B&W 6S46MC-C7
10 100101
102
103
104
105
106
107
Mode1 Mode2 Mode3 Mode4
Num
ber c
once
ntra
tion(
#/cm
3 )
Dp(nm)Mode1 Mode2 Mode3 Mode4
0.00
0.06
0.12
0.18
0.24
0.30
E3 Cycle
FSN
2-st 7.4 MW engine emission measurement
Electro-static precipitator
5th ICCT Workshop September 2018, SF
4. Wet-ESP for 3MW ship engine
Installation and test
WET EP(3 MW PM/BC after-treatment system)
2 st. diesel engineHHI-MAN B&W 6S46MC-c7
Hydraulic Dyno.
Pipe connection between EP and MW engineSupporting frame
installation
Supporting frame installation
Measurement of engine out emissions
Engine monitoring: P, T, atm, back pressure …
Smoke meter
MSS
5th ICCT Workshop September 2018, SF
4. Wet-ESP for 3MW ship engine
Test results
PSA method
Principle
Engine out
Downstream of ESP
FSN method
Principle
Engine out
Downstream of ESP
1st 2nd
1st 2nd
70%
82%
75% 75%82% 86%
1st 2nd
1st 2nd
SO2
(ppm
)
SO2
/CO
2
PM/BC reduction- FSN method: 75-82%
- PAS method: 82-86%
Back Pressure~ 38 mbar
Gaseous emissionsrarely removed
5th ICCT Workshop September 2018, SF
4. Wet-ESP for 3MW ship engine
Test result of the final product
Engine out ESP downstream(66kV)
0.00
0.01
0.02
0.03
0.04
Smok
e (F
SN)
Test condition
91.4 %저감
Engine out ESP downstream(66kV)
0.00
0.11
0.22
0.33
0.44
Soot
con
cent
ratio
n (m
g/m
3 )
Test condition
95.7 %저감
95.3 %저감
Dilution ratio : 10Dilution ratio : 15
FSN method
PSA method
0
200
400
600
800
1000
1200
1400
1200 1500 1800 2100 2400Time [sec]
SO2 c
once
ntra
tion
[ppm
]
SO2: 621.4 CO2 : 4.3 SO2/CO2 ratio : 143.1 (3.304% S)
97.7% 98.6% 96.9% 97.3%
SO2: 528.4CO2 : 4..3SO2/CO2 ratio : 121.8 (2.813% S)
SO2: 611.9CO2 : 4.3 SO2/CO2 ratio : 141.4 (3.265% S)
SO2: 601.7 (1 min. ave.)CO2 : 4.3 (1 min. ave.)SO2/CO2 ratio : 139.1 (3.213% S)
SO2: 14.0 SO2: 8.9 SO2: 16.2 SO2: 16.3
SO2, Ave. reduction rate: 97%
0
500
1000
1500
0 200 400 600 800 1000Time [sec]
SO2 c
once
ntra
tion
[ppm
]
SO2: 1266.6CO2 : 4.4SO2/CO2 ratio : 288.7 (6.668% S)
93.4% 95.5%
82.4%
SO2: 1441.8CO2 : 4..4SO2/CO2 ratio : 329.7 (7.616% S)
SO2: 1160.0 (1 min. ave.)CO2 : 4.3 (1 min. ave.)SO2/CO2 ratio : 267.4 (6.176% S)
SO2: 77.0 SO2: 57.6 SO2: 253.7
Performance of the final product- Back pressure: 31 mbar < 60 mbar
- SOx reduction: 97%
- PM/BC reduction: 91.4% > 90%
PM/BC reduction SO2 reduction
91.4%
95.3% 95.7%
5th ICCT Workshop September 2018, SF
5. Summary and future plan
Summary and future plan
▶DPF system for sub-MW class and wet-ESP for MW class marine engine developed in Korea
▶Real ship installation and proof will be performed soon. Real ship proof of the developed DPF system
(2018-2021, Ministry of Oceans and Fisheries)Development of SCR on DPF system for 500 kW
marine engines(2018-2021, Ministry of Trade, Industry and Energy)
SCR catalyst coated filter
Ship installation scheduled
5th ICCT Workshop September 2018, SF
5. Summary and future plan
Control measures under consideration (IMO PPR CG)
▶ Fuel Type
⁞
▶ Fuel Treatment
⁞
▶ Exhaust gas treatment
Diesel Particulate Filters (DPF)
Electrostatic Precipitators (ESP)
Selective Catalytic Reduction (SCR) with Diesel Particulate Filter (DPF)Covers both SCR combined with DPF in a serial connection, and SCR-F technology. The latter
is a single device which has the functions of both SCR and DPF by coating SCR catalysts on a
filter for DPF. ⁞
Thank you very much for your attention!
Sunho Park
Associate Professor of Mechanical EngineeringDankook UniversityRepublic of Korea
E-mail: [email protected]