European Project Semester

European Project Semester

Alejandro HombravellaAlican Kiliçaslan

Carolin RüssJeremy Perales

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Team Caterpillar:

EUROPEAN PROJECT SEMESTER 2

What is the project about?Plan to achieve the goal:•Scrubber•Catalyst•Boiler•Exhaust Gas Silencer•Funnel•Example exhaust gas cleaning system

Content


To create a catalogue of optimum configurations of exhaust gas cleaning systems for different types of HFO diesel engines to fulfill the IMO 3 criterias

Other main focusses:

•cost of equipment•cost of equipment in action •cost of service•repairing situation and spare parts•place in ship

Goal


IMO 3



Exhaust gas cleaning system?

I would suggest to put also another schema, with more detailed graphics (if exists... )


Exhaust gas cleaning system

Wet exhaust gas cleaning system Dry exhaust gas cleaning systemAn effective and advanced exhaust system must achieve and ensure four main objectives :1 - To reduce noise level by between 40% and 90% through the insertion of silencers end/or silencer-separators;2 - To cool the exhaust, and eject the engine cooling water through the exhaust without excessive back pressure;3 - To site the outlets at the stern of the boat to minimise exhaust fumes on board;4 - To minimize, by the insertion of an adeguate capacity silencer, the risk of water running back up the exhaust and into the engine cylinders, causing serious engine damages.


Time plan

achieve information about system

material, function, cost, dimensions

suppliers of components

examples for existing configurations

create own configurations


ScrubberHow does it work?

Sulphur Oxides SOx (SO2) dissolves within water vapour forming airborne acids.

What is it made of?

Formed from sulphur contained in oil during combustion and refining processes.


Scrubber1. Water ph is elevated with

alkalitysodium hydroxide ( NaOH )

2. Entering exhaust gas streamsulphur oxides are capturedand neutralized by scrubbingwater chemically forming sulphates

3. Cleaned exhaust gas exits

4. Water and sulphides return toprocess collection tank


Scrubber (OPEN LOOP)


Scrubber (CLOSED LOOP)


Scrubber


Scrubber


Summary of integrated scrubberAvoid increased exhaust gas back pressure caused by

cleaning devices.Reduce the amount of equipment needed for SOx-cleaning of

exhaust gases from all relevant combustion units onboard.Provide a higher cleaning performance in port conditions where

the total flow of exhaust gases is smaller than in normal seagoing

conditions, utilising such higher performance as inherent

in some exhaust gas cleaning devices when operated at

reduced exhaust gas flow. Thus all combustion units can use

the same fuel in all areas and all conditions.

Scrubber


Scrubber•Scrubbing is the cheapest way to comply

•Fresh water scrubber is the only technology to:Make zero effluent discharge possibleBe always in control of reduction efficiencyHave the smallest energy consumptionHave no creation of CO2 caused by neutralization process

•Wärtsilä fresh water scrubber solutions are fit for new

building and retrofit, for any engines and boilers’ brands.


Scrubber


Catalytic converter


Catalytic converter


Catalytic converterA catalytic converter (colloquially, "cat" or "catcon") is a device used to reduce the toxicity of emissions from an internal combustion engine. First widely introduced on series-production automobiles in the US market for the 1975 model year to comply with tightening EPA regulations on auto exhaust, catalytic converters are still most commonly used in motor vehicle exhaust systems. Catalytic converters are also used on generator sets, forklifts, mining equipment, trucks, buses, trains, and other engine-equipped machines. A catalytic converter provides an environment for a chemical reaction wherein toxic combustion by-products are converted less-toxic substances.


Functions

Three-way catalytic converters

A three-way catalytic converter has three simultaneous tasks:Reduction of nitrogen oxides to nitrogen and oxygen: 2NOx → xO2 + N2

Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2

Oxidation of unburnt hydrocarbons (HC) to carbon dioxide and water: 2CxHy + (2x+y/2)O2 → 2xCO2 + yH2O

Catalytic converter


These three reactions occur most efficiently when the catalytic converter receives exhaust from an engine running slightly above the stoichiometric point. This is between 14.8 and 14.9 parts air to 1 part fuel, by weight, for gasoline (the ratio for LPG, natural gas and ethanol fuels is slightly different, requiring modified fuel system settings when using those fuels). When there is more oxygen than required, then the system is said to be running lean, and the system is in oxidizing condition.

Catalytic converter


In that case, the converter's two oxidizing reactions (oxidation of CO and hydrocarbons) are favoured, at the expense of the reducing reaction. When there is excessive fuel, then the engine is running rich. The reduction of NOx is favoured, at the expense of CO and HC oxidation. If an engine could be operated with infinitesimally small about the stoichiometric point for the fuel used, it is theoretically possible to reach 100% conversion efficiencies.

Catalytic converter


Since 1981, three-way catalytic converters have been

at the heart of vehicle emission control systems in

North American roadgoing vehicles, and have been

used on "large spark ignition" (LSI) engines since 2001

in California, and from 2004 in the other 49 states LSI

engines are used in forklifts, aerial boom lifts, ice

resurfacing machines and construction equipment.

Catalytic converter


The converters used in those types of machines

are three-way types, and are designed to reduce

combined NOx+HC emissions from 12 gram/BHP-

hour to 3 gram/BHP-hour or less, as mandated by

the United States Environmental Protection

Agency's (EPA) 2004 regulations.

Catalytic converter


A further drop to 2 gram/BHP-hour of NOx+HC

emissions is mandated in (note: NOx is the industry

standard short form for nitric oxide (NO) and nitrogen

dioxide (NO2) both of which are smog precursors. HC

is the industry short form for hydrocarbons). The EPA

intends to introduce emissions rules for stationary

spark ignition engines, to take effect in January 2008.

Catalytic converter


Two-way catalytic convertersFunctionsA two-way catalytic converter has two simultaneous tasks:Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2

Oxidation of unburnt hydrocarbons (unburnt and partially-burnt fuel) to carbon dioxide and water: 2CxHy + (2x+y/2)O2 → 2xCO2 + yH2O

Catalytic converter


Catalytic converter

This type of catalytic converter is widely used on diesel engines to reduce hydrocarbon and carbon monoxide emissions. They were also used on spark ignition (gasoline) engines in USA market automobiles up until 1981, when they were replaced by three-way converters due to regulatory changes requiring reductions on NOx emissions. Reduction of the NOx emissions requires an additional step. Platinum catalysis can be used.


Catalytic converter

Instead of catalysis, for diesel engines a true

reactant, ammonia pyrolyzed in situ from urea, can

be used to reduce the NOx into nitrogen


Catalytic converterThe regulations regarding hydrocarbons vary according to the engine regulated, as well as the jurisdiction. In some cases, "non-methane hydrocarbons" are regulated, while in other cases, "total hydrocarbons" are regulated. Technology for one application (to meet a non-methane hydrocarbon standard) may not be suitable for use in an application that has to meet a total hydrocarbon standard. Methane is not toxic, but is more difficult to break down in a catalytic converter, so in effect a "non-methane hydrocarbon" standard can be considered to be looser. Since methane is a greenhouse gas, interest is rising in how to eliminate emissions of it.


Catalytic converterAttention to global warming!


Boiler

What is the purpose ?To obtain boiled water by heating water or other fluid in a closed vessel.

What is it made of ?Made of steel or wrought iron, assembly by rivetting


Which fuel ?

Combustion : wood, coal, oil or natural gas

Electric steam boilers : resistance or immersion-type heating elements

Boiler


Fire-tube boiler• Tubes of hot gases running through a sealed container of water

•High-pressure

•Horizontal or vertical

Boiler


Boiler

Water-tube boiler• Tubes of water heated externally by the fire

•High-pressure

•Vertical


Fire-tube boiler• Used on all steam

locomotives

BoilerWater-tube boiler• Used on ships

(marine)


For diesel engine, one or two smaller boilers are used on the ship

Boiler on ships


Boiler on ships

Suppliers

•Aalborg Industries•Mitsubishi Heavy Industries, LTD•Kangrim•Garioni Naval•Chromalox


Exhaust Gas Silencer


Exhaust Gas Silencer1. Absorption Principle

Sound waves are directed to a blown material such as steel wool, mineral wool or fibre glass.dissipate with friction into heat. -> acustic noise resorbed exhaust gas goes through a perforated pipe in the blown material.

Good for high frequencies (500-8000Hz) force depends on geometrie of perforation, sound absorption coefficient and apparent density of material very low loss of exhaust gas pressure noise reduction loss maximum 50dB

which is a loss of sound pressure about 300 times


Exhaust Gas SilencerFeatures

low skin temperature (LST) design extra layer of packed acustic/thermal insulation that

reduces heat and noisemaximum aceptable exhaust gas speed between 20-

40m/sec Easy installation in any position

Advanced acustical designThick wall construction for high transmission loss

Reduces noxious fumes and odorsLong life service

Weight from 125-1755kg

Exhaust gas silencer2. Reflexion principle

Empty case with normally 4 chambers.

Different sized rooms combined with shifted

arranged pipes to reflect and deflect the acustic

noise. Also averaging of sound pressure

amplitude and duplicating of acustic noises Pipes with different perforations and sizes. -> improving interference

Hull gets very hot, because it gets in direct contact with exhaust gas I

ncreasing of gas pressure Good for low frequences

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Exhaust gas Silencer

Example: Absorption exhaust gas silencer AGSD 25

Frequenz 500Hz

Reduction of noise 34dB

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Exhaust gas silencer

Size of silencerAcustic velocity = frequence * wave lenght

Acustic velocity in the air = 343m/s

Lenght of silencer wave lenght/2

Example: 100Hz

L = 1,5215m

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SuppliersHUSSLBF

LindenbergLS Luhe-Stahl

Silencer MarineVetusPuck

TaylorUniversal

KaeferMaximAGSD


Funnel


FunnelFunktions:

removal of smoke and exhaus gas identification of the ship-owner company direct the smoke up in the air to disturb nocody bypass the friction resistance don`t foul the decks and ship structures

Appendagevery high funnels little fins to turbulate the exhaus gas and guide it to the horizontal direction

How does it workGas inside is warm and therefor have a lower weight than the cold air outside.So they have to climp up the funnel pipe. They build a room with less air pressure, in which the cold air is going. Gauge pressure is about 0,0009-0,0015 bar, depends on the resistance.


FunnelFunnel area

The required funnel cross-sectional area is determined by the volume of exhaust gases produced by the propulsion plant. Often this area is too great for a single funnel. Early steam vessels needed multiple funnels had 5 when launched, but as efficiency increased new machinery needed fewer funnels.

SuppliersDitco



Dry exhaust gas cleaning system






Documents

European Project Semester