EGC Systems (Rev.3)

EXHAUST GAS CLEANING SYSTEMS
Content
1. Regulatory Background
2. EGCS Technologies
3. Design & Installation through AMC Contribution
ALPHA MARINE CONSULTING LTD.

Regulatory Background
1. Regulatory background
European
Commission
(EC)
IMO USA VGP
Reduction
of SOx, NOx
& Particles Local
MARPOL
requirements
4
ECAs
5
Alternatives for compliance
Critical amongst these regulations are the measures to

reduce sulfur oxide (SOx) emissions inherent to the
relatively high sulfur content of marine fuels. Ship designers,
owners and operators have a number of different routes to
achieve SOx regulatory compliance:
Install new machinery (or

Install an Exhaust Gas
Use low-sulfur marine convert existing machinery
Cleaning System
fuels in existing where possible) designed to
(EGCS) as an after
machinery operate on a low-sulfur
treatment device
alternative fuel, such as LNG
6
Alternatives for compliance
Method + ̶
High operating cost in ECAs
Fuel switch Flexible, Small Fuel change over procedures
(Switch to ULS HFO in investment Lube oil TBN management
ECAs) Fuel availability?
Reduction of NOX & Investment cost

Convert to LNG Particulates LNG availability
Works with HS HFO

EGCS Lowest total lifecycle cost ROI depends on fuel oil price
difference between low S fuel
(Scrubber) Use everywhere oil and high S HFO
Easy operation
7
Distillate vs. Scrubber use
• Can use conventional HFO • Initial investment (US$ 1.5-2.5 m)

Use of HFO • Possible for retrofit • 0,5-3% fuel consumption increase
with • Reduces particulate matter • Requires space for scrubber
(PM) as well as SOx tower and supporting systems
scrubber • Requires chemicals (closed loop)
• Requires integration with ship’s
power management system
• Requires monitoring
Use of • Useable for most engine • Higher fuel cost

configurations • Potential operational issues due
distillate to long-running with low
viscosity fuel
fuel
8
EGCS Technologies
EGC system
A scrubber is a device installed in the exhaust system after the engine(s) or boiler(s) that treats exhaust
gas with a variety of substances, which may include:
 seawater;
 chemically treated fresh water; or
 dry substances;
The aim of this technology is to remove most of the SOx from the exhaust and reduce PM. After passing
through the scrubber system, the compliant exhaust is emitted to the atmosphere.
SOx Reactions in a Scrubber:

Engine Exhaust Gas Chemistry:
S + O2 → SO2 ~ 95% SO2 + H2O → H2SO3 (Sulfurous Acid)
SO2 + ½O2 → SO3 ~ 5%

SO3 + H2O→ H2SO4 (Sulfuric Acid)
10
Dry EGC system
 A dry scrubber does not use water or any liquid to carry out the scrubbing process;
 Calcium hydroxide (Ca(OH)2), or hydrated lime as it is more commonly known, reacts
with the SOx;
 The reaction produces solid calcium sulfate (CaSO4), also known as gypsum. The waste
stream and generated sludge has to be processed before discharge overboard, where
allowed, or stored and discharged to a shore reception facility as a waste substance;
 Large storage capacity for both lime and gypsum may be required;
 Large material handling systems may be required both on the ship and ashore, for
transporting and loading the lime on board and for discharging the gypsum to shore.
Dry scrubbers use granulates

with caustic lime (Ca(OH)2)
that reacts with sulphur
dioxide (SO2) to form calcium
sulfite: Calcium sulfite is then air-
oxidized to form calcium
SO2 + Ca(OH)2 → CaSO3 + sulfate dehydrate or gypsum: Reaction with sulphur trioxide
H2O (SO3) is:
CaSO3 + ½O2 → CaSO4
SO3 + Ca(OH)2 → CaSO4 +
H2O Which with water forms:
CaSO4 • 2H2O (Gypsum)
11
Concepts & Types of Wet EGC system
 The exhaust gas passes through a liquid medium;
 Systems are identified by their operation as either an open loop or closed loop system;
 Hybrid systems offer both methods of scrubbing;
 The most common liquids are untreated seawater and chemically treated freshwater.
There are three operational concepts of

Wet EGC Systems: There are two types of Wet EGC Systems:
Open Loop EGC System
Inline Type
Closed Loop EGC System
U-Type (Venturi)
Hybrid EGC System
12
2.
 An open loop scrubber uses seawater as cleaning medium;
EGCS Technologies
Wet EGC system - Open Loop
 The sea water is filtered for heavy metals and particulate matter;
 The sea water is discharged into the sea containing the sulphur sub-products cleaned
from the exhaust;
 Simple system not requiring large amounts of waste storage and handling on board
(depending on maker’s selection);
 There are issues of water intake quality (alkalinity) in specific areas;
 Some ports and areas may not permit the discharge of the waste water containing
Sulphur:
 Germany, Belgium, Hawaii, Connecticut which is Zero discharge;
 The USCG VGP (3nm) requires a discharge Ph of more than 6.
Na2CO3+H2SO3→Na2SO3+H2O+CO2 (Sodium Sulfite)
Na2SO3+½O2→Na2SO4 (Sodium Sulfate)
Na2CO3+H2SO4→Na2SO4+H2O+CO2 (Sodium Sulfate)
13
Wet EGC system - Open Loop
De-plume unit Exhaust gas fan
Exhaust gas
analyser
Scrubbing
water Sludge
pump Wash water tank
Residence pump
tank
Water
measurement
Water
measurement
14
Wet EGC system - Closed Loop
 A closed loop system uses fresh water;

 The fresh water is chemically treated usually by caustic soda injection;
 Most of the scrubbing agent is re-circulated with only minimal water intake
and effluent discharge;
 These systems avoid the issue of waste water discharge;
 Are more complex, more costly to run, and create waste storage and
handling issues on board.
2NaOH +SO2→Na2SO3+H2O (Sodium Sulfite)
Na2SO3+SO2+H2O→2NaHSO3 (Sodium Hydrogen Sulfite)
NaOH+ H2SO4→NaHSO4+H2O (Sodium Hydrogen Sulfate)
2NaOH +H2SO4→Na2SO4+2H2O (Sodium Sulfate)
15
Wet EGC system - Closed Loop
Exhaust gas fan

De-plume unit
Holding tank
Exhaust gas
analyser
Scrubbing
water pump
Alkali feed
module
Heat
Exchanger
Sludge
tank
Bleed-off
treatment
unit
Water
measurement
Water
measurement
16
Wet EGC system - Components
Open Loop Scrubber components: Closed Loop Scrubber components:

Scrubber Scrubber
Scrubber Salt Wash-water supply Pump Scrubber Wash-water Supply Pump
Sealing Air Fan(s) Effluent Water Recirculation Pump
Scrubber Salt Wash-water Monitor Oil and Soot Separator
Effluent Water Monitoring Alkali (NaOH) storage tank
Control Cabinet Alkali (NaOH) supply pump (s)
Monitoring and Alarm Cabinet
Wash-water recycle tank
(Plus depending on maker)
Effluent Water Discharge Pump Wash-water Cooler
Oil and Soot Separator Scrubber Wash-water Cooling Monitor
EGC Residue Tank Separator/purifier(s)
Sludge Separator Holding (storage) Tank
Residue (sludge) Tank
Effluent Water Monitoring
Sealing Air Fan(s)
Salt Cooling-water Pump
Effluent Water Discharge Pump
Salt Cooling-water Monitor
Effluent Water Monitoring
Control Cabinet
Monitoring and Alarm Cabinet
17
Wet EGC - Hybrid System
 A variation of the closed loop system

 Can operate as an open loop system
while outside special areas
 Changeover from open to closed
loop by changing over the circulating
pump suction from seawater to the
freshwater circulating tank
loop by changing the wash water
discharge from the overboard
discharge to the circulating tank
18
 A variation of the closed loop system

 Can operate as an open loop system
while outside special areas
loop by changing over the circulating
pump suction from seawater to the
freshwater circulating tank
loop by changing the wash water
discharge from the overboard
discharge to the circulating tank
19
Exhaust gas fan

De-plume unit
Buffer tank
Alkali feed
Exhaust gas module Bleed-off
analyser treatment unit
(DAF)
Heat
Exchanger
Water
measurement Holding tank
Water
measurement
20
Closed loop mode
Open loop mode
Cooling water
21
Inline Type
Inline Type
 Slim Profile - Allows the scrubber to fit in existing funnel

casing – Lower Installation Cost
 No Bypass necessary - Reduced space requirements
 Low Pressure Drop Design - Scrubber meets the engine

manufacturer’s back pressure requirements
 Designed for single engine or for multistreaming

operations
 Proper arrangements to eliminate any potential back

flow of water to the engine
22
U-Type (Venturi)
U-Type (Venturi)
 Large Profile - A new funnel is built or the existing is

extended – Higher Installation Cost
 Bypass is required (dry running cannot be achieved) -

More space required - Maintenance or repair is possible
while engine running.
 Pressure Drop Design slightly more than inline -

Increased consumption
 Designed for multistreaming operations
 Venturi pipes make it impossible for water to back flow

to the engine
23
System Monitoring & Recording
Data recording devices to be provided as part of any EGCS installation. Basic system data to be continuously
monitored and recorded automatically:
Wash water pressure Exhaust gas pressure

Time and position
and flow rate and pressure drop
Engine and/or boiler Exhaust gas Exhaust gas SO2 and

load(s) temperature CO2 content
Wash water pH, PAH

and turbidity
24
Design & Installation
through AMC Contribution
Considerations of equipment selection
Equipment
Installation cost
cost Ship size
Operational
area
Equipment Ship type
Selection
Operational
cost Consumables
(Cost/Availability)
Electrical
Maintenance
consumption
26
Considerations of equipment selection
Equipment
Installation cost
cost Ship size
Operational
area
Equipment Ship type
Selection
Operational
cost Consumables
(Cost/Availability)
Electrical
Maintenance
consumption
27
Feasibility study
Feasibility study process

 Short-list selection of the candidate Suppliers
through “macroscopic” evaluation of the
vessel’s operational envelope and
characteristics
 3D Scanning:
Onboard 3D scanning and preparation of
points-cloud for detailed evaluation vessel’s
existing arrangement; this will contribute
towards the final selection of the Supplier
and provide necessary background for the
detailed design (if & when);
28
Feasibility study

 Installation & Structural modifications:
Determination of the scrubber most
favorable location in terms of efficient
operation and modification costs. Rough
indication and determination of the critical
structural modifications including newly
formed areas to accommodate the EGCS
 Determination of the pipe routing (exhaust
and scrubbing water) through interaction
with existing arrangements [not prerequisite
but strongly recommended for receiving
“realistic’ offers from shipyards]
29
Feasibility study

 Rough calculation of the added steel and pipe
weights and subsequent loss of deadweight
 Calculation of the vessel’s new Equipment
Number (EN) for ensuring adequacy of the
existing mooring arrangement (anchors and
robes/cables) – [applicable only when funnel
is extended]
 Recalculation of the vessel’s electric load
balance to determine the effect of the
additional power demand on the vessel’s
operation and subsequent FO consumption –
[Attention to shaft generators and existing
spare breakers!]
30
Feasibility study

 Preparation of list of materials and
dimensions of the pipe lines; [not prerequisite
but strongly recommended for receiving
“realistic’ offers from shipyards]
 Calculation of the vessel’s existing main
ballast water pipe (cross pipe) taking into
consideration the additional flow demand of
the new sea water pumps serving the
Scrubber system – Simultaneous
ballasting/deballasting operations and
exhaust gas cleaning should be assumed
31
Feasibility study

 Preparation of modifications list of the
existing arrangements which will be
subsequently translated in manhours and
costs. [not prerequisite but strongly
recommended for receiving “realistic’ offers
from shipyards]
 Stability aspects in terms of intact stability
criteria and longitudinal strength
32
Detailed design
 Preparation of technical documentation for Class approval

 Arrangement drawings
 Piping (P&ID) & Structural drawings
 Electrical design & analysis
 Pressure Drop Calculations
 Intact & Damage Stability Analysis
 Preparation of technical documentation for Yard

(.. in addition to the above)
 Detailed engineering drawings for fabrication
 Equipment Installation drawings
 Bill of materials for Procurement purposes
 Construction sequence (through modification plan)
33
Installation & Commissioning
 On-site project management of drydock

installation
 Commissioning planning & supervision
 Close co-operation with EGCS

manufacturer
 Third party verification of new-build

installations
 FAT / SAT witnessing
34
Thank you for your attention

EGC Systems (Rev.3)

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EGC Systems (Rev.3)

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EXHAUST GAS CLEANING SYSTEMS

ALPHA MARINE CONSULTING LTD.

IMO USA VGP

Critical amongst these regulations are the measures to

Install new machinery (or

Reduction of NOX & Investment cost

Works with HS HFO

• Can use conventional HFO • Initial investment (US$ 1.5-2.5 m)

Use of • Useable for most engine • Higher fuel cost

SOx Reactions in a Scrubber:

S + O2 → SO2 ~ 95% SO2 + H2O → H2SO3 (Sulfurous Acid)

SO2 + ½O2 → SO3 ~ 5%

Dry scrubbers use granulates

 The exhaust gas passes through a liquid medium;

 Hybrid systems offer both methods of scrubbing;

There are three operational concepts of

Open Loop EGC System

Closed Loop EGC System

Na2CO3+H2SO3→Na2SO3+H2O+CO2 (Sodium Sulfite)

Na2SO3+½O2→Na2SO4 (Sodium Sulfate)

Na2CO3+H2SO4→Na2SO4+H2O+CO2 (Sodium Sulfate)

De-plume unit Exhaust gas fan

 A closed loop system uses fresh water;

2NaOH +SO2→Na2SO3+H2O (Sodium Sulfite)

Na2SO3+SO2+H2O→2NaHSO3 (Sodium Hydrogen Sulfite)

NaOH+ H2SO4→NaHSO4+H2O (Sodium Hydrogen Sulfate)

2NaOH +H2SO4→Na2SO4+2H2O (Sodium Sulfate)

Exhaust gas fan

Open Loop Scrubber components: Closed Loop Scrubber components:

 A variation of the closed loop system

 A variation of the closed loop system

Exhaust gas fan

 Slim Profile - Allows the scrubber to fit in existing funnel

 No Bypass necessary - Reduced space requirements

 Low Pressure Drop Design - Scrubber meets the engine

 Designed for single engine or for multistreaming

 Proper arrangements to eliminate any potential back

 Large Profile - A new funnel is built or the existing is

 Bypass is required (dry running cannot be achieved) -

 Pressure Drop Design slightly more than inline -

 Designed for multistreaming operations

 Venturi pipes make it impossible for water to back flow

Wash water pressure Exhaust gas pressure

Engine and/or boiler Exhaust gas Exhaust gas SO2 and

Wash water pH, PAH

Feasibility study process

Feasibility study process

Feasibility study process

Feasibility study process

Feasibility study process

 Preparation of technical documentation for Class approval

 Preparation of technical documentation for Yard

 On-site project management of drydock

 Commissioning planning & supervision

 Close co-operation with EGCS

 Third party verification of new-build

 FAT / SAT witnessing

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