methanol as engine fuel: challenges and...

© Wärtsilä

METHANOL AS ENGINE FUEL: CHALLENGES AND OPPORTUNITIES

Toni Stojcevski

6/29/2016 Toni Stojcevski / Wärtsilä

© Wärtsilä INTERNAL© Wärtsilä

REGULATION DRIVERS - IMPACT ON THE ENVIRONMENT

2

LOCAL

GLOBAL

LOCAL

LOCAL

Acid rains

Tier II (2011)

Tier III (2016)NOx

Greenhouse effect

Under evaluation by IMO

EEDI / SEEMPCO2

Acid rains

Sulphur content in fuel

SECA (2015) – Global 2020/2025SOx

Direct impact on humans

Locally regulated

Particulatematter

Particulates <10μ

3,7 mil / year premature deaths worldwide[1]

Sources: [1] WHO, 2014, Fact sheet No 313; 2 NOAA; 3IIASA ; 4 IPCC

NOx

$562 bil / year

Global health related costs [3]

SOx

Responsible for 50%

of particulates in the air [2]

CO2

$1tr - $3tr “Coping cost”

(1-5% of GDP in 2014) [4]

© Wärtsilä INTERNAL3

ENVIRONMENTAL LEGISLATION CONTINUES

2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2025

SOx legislation:• Sulphur free fuels

– LNG

– Methanol, LPG, bio-fuels

– Distillates

• Scrubbers in combination with HFO

NOx legislation:Tier II

• Engine internal methods

Tier III

• Secondary methods (SCR)

• LNG/NG with lean burning process (dual-fuel

engines)

Ballast Water Treaty:• UV ballast water treatment system

• EC ballast water treatment system

• Minimised amount of ballast water through

Ship Design

Global cap 0.5% SOx

Global Ballast Water Management Treaty

NOx Tier III in NECA(North America)

NOx Tier II(Global)

Global 0.5% SOx

limit reviewed

All ECA 0.1% SOx

North Europe ECA 1% SOx

0.1% SOx

in EU ports Global cap 3.5% SOx

US Ballast Water Management Treaty

North America ECA 1% SOx


WHERE TO GO? NO “SILVER BULLET” SOLUTION

4

© Wärtsilä INTERNALINTERNAL5 ©

Wärtsilä

0 5 10 15

50DF

20DF

46DF

0.6 -1.8 MW

3,0 – 10,0 MW

6.2 -18.3 MW

5.8- 17.5 MW

20

34DF

• LNG Carriers

• Cruise ships

• RO-RO/PAX

• Ferries

• Large Offshore Units

• Small LNG / CNG

vessel

• Small cargo vessels

• Supply vessel

• Offshore application &

Production

• Aux. engines with

W50DF

• LNG Feeder

• Jack-up

• Tugs

• Small cargo vessels

• Barges

• Small ferries

• Aux. engines with

W34DF & W50DF

• LNG Carriers

• Cruise ships

• RO-RO/PAX

• Ferries

• Large Offshore Units

31

4,2 – 8,8 MW

DUAL FUEL (GAS/FUEL OIL) ENGINE PORTFOLIO & APPLICATION TYPES

Which engine platforms to be developed for Methanol use

will be defined based on market demand.

© Wärtsilä INTERNALINTERNAL

Wärtsilä dual-fuel references>1,500 engines > 16 million running hours

6

DUAL-FUEL EXPERTISE

MERCHANT

881 ENGINES

204 LNG carriers

14 Tankers

11 LPG carriers

4 Containers

3 Bulk carriers

2 Car carriers

SPECIALS

46 ENGINES

16 IWW vessels

6 Tugs

1 Navy vessel

1 Icebreaker

1 Hopper Dredger

1 Guide ship

1 Cable Layer vessel

DUAL-FUEL

CONVERSION

36 ENGINES

4 FPSO vessels

3 Ferries

2 RORO vessels

1 IWW vessel

1 Chemical tanker

2 STROKE

DUAL-FUEL

35 ENGINES

10 Large LNG

carriers, 2 engines

each

6 Container Feeder

vessels

4 Chemical tankers

4 Asphalt Carriers

1 Small LNG carrier

OFFSHORE

132 ENGINES

24 Offshore supply

vessels

6 FPSO vessels

2 FSO vessels

1 Jack-Up rig

DUAL-FUEL

POWER PLANTS

376 ENGINES

82 plants

Output 5,031 MW

Online since 1997

CRUISE & FERRY

66 ENGINES

12 Ferries

3 ROPAX vessels

1 Cruise and ferry


ALTERNATIVE CLEAN FUELS (BESIDES LNG)

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

In service today

for 34SG

In Service

Several VOC

recovery

installations in

use

GasReformer

delivered 2013

DF engines in

marine service

since 2001

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 SECA

NECASECA

NECA

SECA

NECA

6

NECA


FUEL PROPERTIES

8

Units Methanol LNG Bunker Fuel

Molecular formula CH3OH >90% CH4 CnH1.8n C8-C20

Carbon Content (wt%) 37.49 ~75 ~87

Density kg/l 0.79 0.44 (LNG) 0.85

Water Solubility Complete No No

Boiling point °C 65 -162 150-370

Flash point °C 11 -188 min.60

Auto ignition °C 464 540 240

Viscosity cSt@20°C ~0.6 n.a. ~13.5

Octane RON/MON 109/89 120/120 -

Cetane No. - 5 - 45-55

LHV MJ/kg 20 45 42

Flammability limits Vol% 7-36 5-15 1-6

Flame speed cm/s 52 37 37

Heat of evaporation kJ/kg 1178 n.a. 233

Stoichiometric AF ratio - 6.45 17.2 14.7

Adiabatic flame temp. °C 1910 1950 2100

Bulk modulus MPa 777 848 1350

Sulphur content % 0 0 3.5 max

© Wärtsilä INTERNAL

Nitrogen

Generator

Oil unit

Diesel pump

Water tank for dilution of

fuel return

Methanol tank and

LP feed system

EHSV

SSV

SSV: Shutdown and Safety Valve

EHSV: Electro-Hydraulic Solenoid Valve

* All methanol lines can be flushed with nitrogen.

Nitrogen purge*

Sealing oil

Control oil

Methanol

Methanol pump

TECHNOLOGY – MD SYSTEM LAYOUT

• Pilot-fuel assisted diesel combustion concept

• Methanol is combusted according to the diesel process. Methanol is injected close to TDC

and ignited by a small amount of diesel pilot fuel.


HP METHANOL PUMP

10


WÄRTSILÄ METHANOL – DIESEL, ON ENGINE PIPING

11


METHANOL INJECTOR - THE HEART OF THE METHANOL ADAPTATION

ACCUMULATOR

BLOCKCONTROL

BLOCKTRANSFER

BLOCK

The methanol injector allows the engine to run on

methanol ignited by pilot fuel or on pure diesel.

© Wärtsilä INTERNAL

CONTROL OIL

FROM SOLENOID VALVE

METHANOL

FROM METHANOL HP PUMP

PILOT DIESEL

FROM DIESEL JERK PUMP

FLOW FUSE

ACCUMULATOR

SEALING OIL

AT METHANOL SEALING SURFACES

+ AROUND METHANOL NEEDLES

SEALING

OIL

CONTROL

PISTON

TRIANGULAR

PLATE

DIESEL

NOZZLE

METHANOL INJECTOR WORKING PRINCIPLE


PHI T MAPS – NOX & PPM

14

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


INITIAL TEST RESULTS OF WÄRTSILÄ SULZER ZA40S-MD

15

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

ari

ne

Sp

ecif

ic IS

O 8

17

8 C

orr

[g

/kW

h]

BMEP [bar]

ZA40S_reference

Z40_reference 2014_LFO_CS

Z40_reference 2003_HFO_CS

Z40_load swing_450bar pinj


200

250

300

350

400

450

500

550

600

650

0 5 10 15 20 25 30

t5 T

em

p 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


150

200

250

300

350

400

0 5 10 15 20 25 30

t6 T

em

p E

xh P

ipe

[°C

]

BMEP [bar]

ZA40S_reference

Z40_reference 2003_HFO_CS_norm

Z40_reference 2014_LFO_CS_norm



160165170175180185190195200205210215220225230235240245

0.00 20.00 40.00 60.00 80.00 100.00 120.00

Tota

l BS

FC

LH

V C

orr

ect

ed

[g

/kW

h]

Engine Power % [%]

Z40_reference




Z40_reference_HFO_2003

~2%

* Preliminary tests - Engine consumption

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

Filt

er S

mo

ke N

um

be

r M

ea

s 1

[F

SN

]

BMEP [bar]

ZA40_reference

Z40_reference 2003_HFO_CS




*

© Wärtsilä INTERNAL© Wärtsilä16

• Adaptation of proven engine technology, minor modification to the engine

• No reduction in efficiency or output when running on methanol

• Load response unchanged, full fuel redundancy

• Existing fuel or ballast tanks can be converted into 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

ENGINE CONVERSION KIT – SUMMARY

© Wärtsilä INTERNALINTERNAL

Natural Gas (CH4)

LNGMeOH

New costly

infrastructure

η=90%η=~70%

Existing

infrastructure

Renewable methanol possible

AVAILIBILITY - MEOH & LNG, TWO OPTIONS TO TRANSPORT NG

6/29/2016 Toni Stojcevski / Wärtsilä

© Wärtsilä 6/29/2016

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

MethanolReference

ship

SO2 2 29 ton

NOx 56 56 ton

PM2.5 4 32 ton

Fuel use 632 632 TJ

SECA compatible? yes yes

NECA compatible? yes yes

EmissionsMonetized benefits

SO2 28 ton

NOx 0 ton

PM2.5 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

Toni Stojcevski / Wärtsilä


CHALLENGES

19

Technical

• no issues with corrosion in the combustion chamber due to diesel cycle

‒ fuel combusted directly

• material choice important

‒ special alloys, coatings and sealing materials

• design criteria important

‒ special design for sealing surfaces

Economical

• price disconnection from bunker fuel market

• availability, >60 export/import terminals, how to bunker?


FUTURE POSSIBLE DEVELOPMENT - RECOMMENDATIONS

20

• Variable injection timing for both pilot and main fuels

• Separate pilot fuel injector -> minimizing the pilot fuel amount

• Water-blended methanol -> lower NOx

• Pure methanol mode – diesel combustion cycle – hot surface assisted ignition

THANK YOU

methanol as engine fuel: challenges and...

Documents