METHANOL AS ENGINE FUEL: CHALLENGES AND …...INITIAL TEST RESULTS OF WÄRTSILÄ SULZER ZA40S-MD ... Technology : Available for ZA40S engines today, Pilot Installation Q1 2015, Concept

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METHANOL AS ENGINE FUEL: CHALLENGES AND OPPORTUNITIES

Sjöfartens Dag / Maritime Day 12.5.2016 Mariehamn

Toni Stojcevski

5/16/2016 Toni Stojcevski / Wärtsilä

© Wärtsilä 5/16/2016

WHY WE NEED TO CHANGE?

Emissions and their socio-economic impact

Particulates <10µ 3,7 mil / year Premature deaths worldwide[1]

SOx50% Responsible of particulates in the air

50 million carsEquivalent of 1 Mega tanker

(60 MW HFO engine) [2]

NOx $562 bil / year Global health related costs [3]

VOC’s 470K / year Ozone caused premature deaths [4]

CO2 $1tr - $3tr “Coping cost” (1-5% of GDP in 2014) [5]

Air pollution €390 – 940b / year EU health related costs (Avg. 5% GCP) [6]

Sources: [1] WHO, 2014, Fact sheet No 313; 2 NOAA; 3IIASA ; 4 IOP; 5 IPCC; 6EU commission ;

Toni Stojcevski / Wärtsilä

© Wärtsilä

LOCAL

GLOBAL

LOCAL

LOCAL

Acid rainsTier II (2011)Tier III (2016)

NOx

Greenhouse effectUnder evaluation by IMOEEDI / SEEMP

CO2

Acid rainsSulphur content in fuelSECA (2015) – Global 2020/2025

SOx

Direct impact on humansLocally regulated

Particulatematter

REGULATION DRIVERS - IMPACT ON THE ENVIRONMENT



WHERE TO GO?



AVAILIBILITY TECHNOLOGY

REGULATIONS

METHANOL INTO SHIPPING INDUSTRY CONTEXT


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Regulations Technology

Availability

IMO / World BankFlag State / Local Class compliance

Fuel supplyLT Contracts (bankable)

InfrastructureOpex

Existing / NewDiesel / Otto

Conversion / New buildCapex

METHANOL AS FUEL – MARKET DYNAMICS


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New and existing vessel• Will cause an extensive need for ship owners to invest in

existing fleet

Only new buildings

Affecting vessels in different ways

SOx

• SECA areas 0,1% sulphur by 1st of January 2015

• Globally 0,5% sulphur by 1st of January §

NOx

• IMO Tier II in force

• IMO Tier III by 1st of January 2016 in NECA areas

REGULATIONS REQUIRING INVESTMENTS


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In Service

First installation in service since Q1 2015

Promising pilot results

Full engines test on ZA40 have taken place during 2014

Methanol• Sulfur free

• Low Nox

• Ultra low particulates

Bio-fuels• Sulpfur free• Fuel specification

and availability is a question mark

VOC• Mix of different HC´s

and inert gas• VOC from a shuttle

tanker can cover 20% of energy demand

LPG• Sulfur free• Heavier than air• 2% of global

energy market

In Service

In service since 2012

Operating on Bio-Fuel or MDO

Several land based power plants in operation

Tested in the 90`s

Challenge with injection pressure with the diesel principle

Smoke problem

Plant was transferred back to liquid fuel

In Service

Several VOC recovery installations in use

GasReformerdelivered 2013

DF engines in marine service since 2001

SECA

NECA

Ethane• C2H6• Sulfur free• Interesting when

available as cargo

In Service

DF engines running on ethane in service since 2015

Approval in principle

SECA

NECA

SECA

NECA

SECANECA(Otto Principle)

SECANECA(Otto Principle)

ALTERNATIVE CLEAN FUELS (BESIDES LNG)


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HFO + EGC MGO LNG Methanol

ComplianceNowFuture

Availabilty

EconomicsCapexOpex

TECHNOLOGY – RETROFIT OPTIONS



REGULATIONS – CLASS COMPLIANCE IGF CODE, MEOH VS LNG


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Fuel Methanol Natural Gas Diesel (bio-diesel similar)

Density (kg/l)* 0.79 0,44 (as LNG 0,85

Boiling point (°C) 65 -162 150-370

Flash point (°C) 11 -188 min. 60

Auto ignition (°C) 464 540 240

Viscosity cSt at 20°C ~ 0,6 na ~ 13,5

Octane RON/MON 109/89 120/120 -

Cetane No. <5 - 45-55

LHV (MJ/kg) 20* 50 42

Flammability Limits, Vol% 7-36 5-15 1-6

Flame Speed (cm/s) 52 37 37

Heat of Evaporation (kJ/kg) 1178 na 233

Stoichiometric Air-Fuel Ratio 6,45 17,2 14,7

Adiabatic flame temp. (°C) 1910 1950 2100 * 2,17:1 Methanol:Diesel

CnH1.8n

C8-C20

METHANOL CHARACTERISTICS COMPARED



• Methanol is combusted according to the diesel process. The methanol is injected close to TDC and ignited by a small amount of diesel pilot fuel.

• The methanol injection pressure is ~500 bar.

WÄRTSILÄ METHANOL - DIESEL RETROFIT SOLUTION


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Nitrogengenerator

Oil unit

Diesel pump

Water tank for dilution of fuel return

Methanol tank and LP feed system

EHSVSSV

SSV: Shutdown and Safety ValveEHSV: Electro-Hydraulic Solenoid Valve* All methanol lines can be flushed with nitrogen.

Nitrogen purge*10 bar

Sealing oil 700 bar

Control oil 350 bar

Methanol 600 bar

Methanol pump

TECHNOLOGY – MD SYSTEM LAYOUT

Toni Stojcevski / Wärtsilä5/16/2016

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WÄRTSILÄ METHANOL - DIESEL ON ENGINE PIPING


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CONTROL OIL 370 barFROM SOLENOID VALVE

METHANOL 600 barFROM METHANOL HP PUMP

PILOT DIESELFROM DIESEL JERK PUMP

FLOW FUSE

ACCUMULATOR

SEALING OIL 700 barAT METHANOL SEALING SURFACES

+ AROUND METHANOL NEEDLES

SEALINGOIL

CONTROLPISTON

TRIANGULARPLATE

DIESELNOZZLE

COOLING OIL 10 barCIRCULATES IN GALLERIES

AROUND THE NOZZLE BODY

DIESEL FUNCTIONAL LEAKAGEDEDICATED COLLECTION LINE

MIXED LEAKAGESCONTROL OIL, SEALING OIL

FUNCTIONAL + FROM POSSIBLE SEALING SURFACE FAILURE

METHANOL INJECTOR


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Source: SAE 2016-01-0887 , Svensson et al. , Lund University

PHI T MAPS – NOX & PPM

Zero particulates , much lower NOx

Typical Diesel FuelMethanol Fuel

“soot”

“soot”NOx NOx


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0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

0.00 5.00 10.00 15.00 20.00 25.00 30.00

Filte

r Sm

oke

Num

ber M

eas

1 [F

SN

]

BMEP [bar]

ZA40_reference

Z40_reference 2003_HFO_CS

Z40_reference 2014_LFO_CS

Z40_load swing_450bar pinj


0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

0.00 5.00 10.00 15.00 20.00 25.00 30.00

NO

x M

arin

e S

peci

fic IS

O 8

178

Cor

r [g

/kW

h]

BMEP [bar]

ZA40S_reference

Z40_reference 2014_LFO_CSZ40_reference 2003_HFO_CSZ40_load swing_450bar pinjZ40_load swing_600bar pinj

200

250

300

350

400

450

500

550

600

650

0 5 10 15 20 25 30

t5 T

emp

b Tu

rbin

e [°C

]

BMEP [bar]

ZA40S_reference

Z40_reference 2003_HFO_CS_norm

Z40_reference 2014_LFO_CS_norm

Z40_load swing_450bar pinj_norm

Z40_load swing_600bar pinj_norm

160165170175180185190195200205210215220225230235240245

0.00 20.00 40.00 60.00 80.00 100.00 120.00

Tota

l BSF

C L

HV

Cor

rect

ed [g

/kW

h]

Engine Power % [%]

Z40_reference

Z40_reference 2014_LFO_CS



Z40_reference_HFO_2003

~2%

* Preliminary tests - Engine consumption

- Further investigation on engine efficiency to be performed

- (Heat Balance and heat release to be calculated)

*

No reduction in output and load response unchanged

Full fuel redundancy

INITIAL TEST RESULTS OF WÄRTSILÄ SULZER ZA40S-MD


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Cost

Capex: Not a “complex” conversion; feasible ROI

Opex: Methanol fuel prices competitive? to (MGO/MDO,LSFO)

Availability

Fuel: Liquid, widely used in chemical industry, Can utilize existing transport and terminal infrastructure

Technology : Available for ZA40S engines today, Pilot Installation Q1 2015, Concept for other engines available, pilot projects research

METHANOL OVERVIEW: AVAILABILITY & COST


© Wärtsilä 16.5.201620

FUEL PRICES

0,00

10,00

20,00

30,00

40,00

50,00

60,00

70,00

Feb

May

Aug

Nov

Feb

May

Aug

Nov

Feb

May

Aug

Nov

Feb

May

Aug

Nov

Feb

May

Aug

Nov

Feb

May

Aug

Nov

Feb

2010 2011 2012 2013 2014 2015 2016

EU

R /

MW

h

Nat Gas (Spot) TTF (NL) EUR/MWh LNG Japan EUR/MWhNat Gas (Spot) Henry Hub EUR/MWh HFO 380 Centistoke Rotterdam EUR/MWh

HFO 180 Centistoke Rotterdam EUR/MWh Marine Gas Oil Rotterdam EUR/MWh

MDO Rotterdam EUR/MWh LSFO 1 % Fair Value NWE EUR/MWh

Methanol Rotterdam EUR/MWh

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FUTURE OF NATURAL GAS

2012: An Interdisciplinary MIT Study - findings

“The potential for natural gas to reduce oil dependence could be increased by conversion into room temperature liquid fuels that can be stored at atmospheric pressure. Of these fuels, methanol is the only one that has been produced for a long period at large industrial scale. Methanol has the lowest cost and lowest GHG emissions, but requires some infrastructure modification and faces substantial acceptance challenges.”

2015: Gal Luft – IAGS”Methanol provides natural gas an entry point to markets where it is currently underutilized ... Despite its price and environmental advantages over diesel fuels, natural gas powers today small fraction of the world’s shipping … By any yardstick, methanol is the most attractive carrier for natural gas.”


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Natural Gas (CH4)

LNGMeOH

New costly infrastructure

η=90%η=~70%

Existing infrastructure

Renewable methanol possible

AVAILIBILITY - MEOH & LNG, TWO OPTIONS TO TRANSPORT NG


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Ballast tank convertedto methanol fuel tank

Pump room

Double walledfuel pipes

Engines converted for methanol combustion

STENA GERMANICA – CONVERSION SCOPE


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Engine conversion to dual fuel

New electrical installation

High pressure pipes

New engine control system for all four engines

High pressure pumpsMethanol storage tank painted with zinc silicate

METHANOL ADAPTATION


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ENGINE BEFORE AND AFTER CONVERSION


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• Adaptation of proven engine technology, minor modification to the engine• No reduction in efficiency or output running on methanol • Load response unchanged, full fuel redundancy • Existing fuel or ballast tanks can be converted to methanol tanks• Short off-hire time, can be done engine by engine• Lower thermic load on the engine• Much lower NOx, SOx, and PM (particulates), good base for future ECA regulations• Available methanol infrastructure (bunker fuel to be developed)

ENGINE CONVERSION KIT – FEATURES

5/16/2016 Toni Stojcevski / Wärtsilä5/16/2016

© Wärtsilä

Regulations� IMO / World Bank� Flag State / Local� Class ComplianceAvailability� Fuel supply � Long term contracts (bankable)� Infrastructure (could be easily developed)� Opex (fuel price disconnection)Technology� Excellent test results and pilot project operating� Capex (pilot, to be optimized)

FulfilledTo a great extent

(not used as marine bunker fuel)

CAN WE TICK ALL THE BOXES WITH METHANOL?



Case study 3: Pilot methanol vs. Reference shipMonetized annual benefits – central estimate (low & high)

Pilot methanol vs. Reference ship

Human Health 563 (261-1316) KEUR

Crop damages 0 KEUR

TOTAL 563 (261-1316) KEUR

EMISSIONS & SOCIOECONOMIC BENEFITS – CASE STUDY

Pilot Methanol

Reference ship

SO2 2 29 tonNOx 56 56 ton

PM2.5 4 32 tonFuel use 632 632 TJ

SECA compatible? yes yesNECA compatible? yes yes

EmissionsMonetized benefits

SO2 28 tonNOx 0 tonPM2.5 28 ton

Emission reduction

High benefits, even without NOx reduction effect

Source: ZVT, IVL, Erik Fridell, Stefan Åström, 2015

“As air quality improves in response to legislation, its public health impact will fall by 2020 across Europe. As a result, public health costs of air pollution are expected to fall from €803 billion a year in 2000 to €537 billion in 2020. The number of people dying prematurely from the effects of air pollution is calculated to fall from around 680,000 people in 2000, to around 450,000 in 2020.” Source: EC – Science for Environmental Policy



SCENARIOS FOR RENEWABLE FUELS


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The same infrastructure for Shipping and Land transport

Methanol bunkering NG-Methanol +Production of DME for trucks

Waste to methanolEnerkem

NG-Methano l

CO2-ElectrofuelCRI

Volvo DME trucks

Wärtsilä Methanol Engines

Methanol fuel blendingM-15, M-85 or M-100

NG-Methanol is ultimate transition fuel toFossil free fuel society

Leaders of the industry should conduct their business in a way that doesn't always benefit them only but benefits the society in whole

METHANOL - THE BRIDGE TO A FOSSIL FREE FUEL SOCIETY


THANK YOU!

Toni Stojcevski+46 706 656115

[email protected]

Documents

METHANOL AS ENGINE FUEL: CHALLENGES AND …...INITIAL TEST RESULTS OF WÄRTSILÄ SULZER ZA40S-MD ... Technology : Available for ZA40S engines today, Pilot Installation Q1 2015, Concept