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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: sunhopark@dankook.ac.kr