DUAL FUEL ENGINES

LATEST DEVELOPMENTS
Oskar Levander, Director, Concept design, MLS
HAMBURG, 27.9.2011

Wrtsil

27 September 2011

Oskar Levander

Content

Environmental and market drivers

LNG as a marine fuel
DF engines
RoRo concept design
Machinery and fuel comparison
Conclusions

Wrtsil

27 September 2011

Oskar Levander

Factor trends: Environment

LOCAL

LOCAL

NOx

Acid rains
Tier II (2011)
Tier III (2016)

LOCAL

Wrtsil

Acid rains
Sulphur content in fuel

GLOBAL

Particulate
matter

SOx

27 September 2011

Direct impact on humans

Locally regulated

Oskar Levander

CO2

Greenhouse effect
Under evaluation by IMO

Until now..

Wrtsil

27 September 2011

Oskar Levander

From now on.

Established Emissions Controlled Areas

Emissions Controlled Areas under consideration

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27 September 2011

Oskar Levander

NOx reduction IMO requirements and methods

Specific NOx emissions (g/kWh)

Tier I (present)

18
16

Dry methods (engine optimization)

14

- Concepts are ready

12

Ships built 2000 onwards

Engines > 130 kW
Retrofit: Ships built
1990 2000
Engines > 90 litres/cylinder
and > 5000 kW
Wrtsil: RTA, W46, W64

10
8

- SCR Catalyst
- Alternative pathways under

6
4

Ships keel laid 2011 onwards

Engines > 130 kW

investigation (Combined measures)

Tier III (ECAs 2016)

2
0
0

200

400

600

800

1000 1200 1400 1600 1800 2000

Rated engine speed (rpm)

Tier II (global 2011)

Wrtsil

27 September 2011

Oskar Levander

Ships in designated
areas, keel laid 2016
onwards
Engines > 130 kW

IMO Sulphur Limits

4,5%
World

3,5%

1,5%
ECA

1,0%
0,5%
0,1%

Wrtsil

27 September 2011

Oskar Levander

2022

2021

2020

2019

2018

2017

2016

2015

2014

2013

2012

2011

2010

2009

2008

EU in ports

Machinery options

Main options for operations inside ECA

MGO + SCR
HFO + Scrubber + SCR
LNG

Wrtsil

27 September 2011

Oskar Levander

Greenhouse emission reductions

The society is demanding lower CO2 emissions from ships

IMO is trying to respond the demand by introducing guidelines for:
Energy Efficiency Design Index (EEDI)
Energy Efficiency Operational Index (EEOI)
Market based instruments

Wrtsil

27 September 2011

Oskar Levander

Fuel prices
35
LNG Japan average [USD/MBtu]

30

NG Henry hub [USD/MBtu]

HFO 380cst Rotterdam [USD/MBtu]

25

USD/MBtu

MGO Rotterdam [USD/MBtu]

20
15
10
5

O
ct
-0
Fe 1
b0
Ju 2
n0
O 2
ct
-0
Fe 2
b0
Ju 3
n0
O 3
ct
-0
Fe 3
b0
Ju 4
n0
O 4
ct
-0
Fe 4
b0
Ju 5
n0
O 5
ct
-0
Fe 5
b0
Ju 6
n0
O 6
ct
-0
Fe 6
b0
Ju 7
n0
O 7
ct
-0
Fe 7
b0
Ju 8
n0
O 8
ct
-0
Fe 8
b0
Ju 9
n0
O 9
ct
-0
Fe 9
b1
Ju 0
n1
O 0
ct
-1
Fe 0
b1
Ju 1
n11

Sources: www.lngoneworld.com, www.bunkerworld.com, LR Fairplay

10

Wrtsil

27 September 2011

Oskar Levander

Cleaner Exhaust Emissions with LNG

25-30% lower CO2

Thanks to low carbon to hydrogen ratio of fuel

85% lower NOX

Lean burn concept (high air-fuel ratio)

No SOX emissions
Sulphur is removed from fuel
when liquefied

Very low particulate emissions

No visible smoke
No sludge deposits

11

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27 September 2011

Oskar Levander

DF ENGINES

12

Wrtsil

27 September 2011

Oskar Levander

Otto or Diesel cycles: effects on NOX

Nikolaus August
Otto

Rudolf Christian Karl

Diesel

Flame front propagation

Fuel spray

NOX formation

13

Wrtsil

27 September 2011

Otto or Diesel cycles: effects on NOX

Big temperature
difference
NOx formation!

Diesel, max flame temp.

Otto, max flame temp.
14

Wrtsil

27 September 2011

Select the right technology

DUAL-FUEL (DF)
****
*
*** ***

Meets IMO Tier III

GAS INJECTION

SPARK-IGNITION GAS (SG)

*********
*
*** ***

Meets IMO Tier III

No redundancy
No HFO flexibility

GAS INJECTION

GAS-DIESEL (GD)
*

Does NOT meet IMO Tier III

High gas pressure

GAS INJECTION

15

Wrtsil

27 September 2011

Oskar Levander

Gas burning technologies

GAS-DIESEL
(GD)

DUALFUEL (DF)

1992

1987

SPARK-IGNITION
GAS (SG)

16

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27 September 2011

Oskar Levander

1995

The marine favourite technology?

DUAL-FUEL (DF)
****
*
*** ***

Meets IMO Tier III

GAS INJECTION

SPARK-IGNITION GAS (SG)

*********
*
*** ***

Meets IMO Tier III

No redundancy
No HFO flexibility

GAS INJECTION

GAS-DIESEL (GD)
*

Does NOT meet IMO Tier III

High gas pressure

GAS INJECTION

17

Wrtsil

27 September 2011

Oskar Levander

Wrtsils choice
DUAL-FUEL (DF)
****
*
*** ***

Meets IMO Tier III

GAS INJECTION

18

IMO Tier III compliant

Low pressure gas

Fuel flexibility; GAS, MDO and HFO

Wrtsil

27 September 2011

Oskar Levander

Dual-fuel engine characteristics

High efficiency
Low gas pressure
Low emissions, due to:

High efficiency
Clean fuel
Lean burn combustion

Fuel flexibility

Gas mode
Diesel mode

Three engine models

19

Wrtsil 20DF
Wrtsil 34DF
Wrtsil 50DF

Wrtsil

27 September 2011

Oskar Levander

Dual-fuel engine range

20DF

6L20DF

1.0 MW

8L20DF

1.4 MW

9L20DF

34DF

6L34DF
9L34DF
12V34DF

1.5 MW

2.7 MW
4.0 MW
5.4 MW

16V34DF

7.2 MW

20V34DF
50DF

6L50DF

9.0 MW
Higher output for 60Hz / Main engines

5.85 MW

8L50DF

7.8 MW

9L50DF

8.8 MW

12V50DF

11.7 MW

16V50DF

15.6 MW

18V50DF
0
20

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27 September 2011

Oskar Levander

17.55 MW
5

10

15

Wrtsil successfully tests new

2-stroke dual-fuel gas engine technology
Wrtsil Corporation, Trade & Technical press release, 23 September 2011:

Wrtsil successfully tests new 2-stroke dual-fuel gas engine

technology to comply with IMO Tier III emission limits
The on-going tests show that the Wrtsil 2-stroke gas engine
performance is in compliance with the upcoming IMO Tier III NOx
emission limits, thereby setting a new benchmark for low-speed
engines running on gas.

21

Wrtsil

27 September 2011

Oskar Levander

Dual-Fuel advantages

Main advantages of the Dual-Fuel 4-stroke engine compared to SG:

22

Redundancy, backup without interruptions in power or speed.

Able to operate on liquid fuel outside ECA-area (incl HFO)
Simple system, no PTI/take me home or double gas system needed.
Vessel re-routing possible, gas supply not a limitation

Wrtsil

27 September 2011

Oskar Levander

Dual-Fuel applications References

Power
Plants

Merchant

Offshore

Cruise
and Ferry

Navy

DF Power Plant
49 installations
155 engines
Online since1997

LNGC
68 vessels
254 engines
950000 rh
Conversion
1 Chem. Tanker
2 engines conv.
Complete gas
train
Complete design

PSVs/FPSOs
22 vessels
78 engines
Online from 1994

LNG ferries
1+1 vessels
4 engines per
vessels
Complete gas
train
2800 passengers
In service in 2013

Costal Patrol
Coming

4 segments 140 installations > 3000000 running hours

23

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27 September 2011

Oskar Levander

Viking Line 2800 Pax Cruise Ferry

The industry's most environmentally
sound and energy efficient large
passenger vessel to date.

Machinery:
Main Engines:
Output:

4 x Wrtsil 8L50DF
4 x 7600 kW

Main particulars:
Overall length:
Breadth, moulded:
Cruising speed
Passengers:
Class:
Ice class:
In service:
Shipyard:
Ship Owner:

24

Wrtsil

27 September 2011

214.0 m
31.8 m
22 knots
2800
LR
1A
2013
STX Finland Oy
Viking Line

Oskar Levander

LNGPac 200
2 x 200 m3
Integrated tank and aux. rooms
Bunkering system, Safety systems
GVU in enclosure
Cold recovery for HVAC

Conversion of Bit Viking

25

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Oskar Levander

Conversion of Bit Viking

26

Wrtsil

27 September 2011

Oskar Levander

LNGpac Main Components

Pressure build
up evaporator

Main Engine Room

Bunkering line,
insulated pipes
Tank room

Gas
Valve

GVU

Water/Glycol
system

Bottom tank
filling

LNG gas evaporator

27

Wrtsil

27 September 2011

Oskar Levander

Bunkering
Station

Gas Valve Unit in enclosure

Main features
Can be located in the same engine
room, dedicated compartment not
needed
Compact design and easy installation
(plug-and-play concept)
Integrated ventilation system when
combined with LNGPac

28

Wrtsil

27 September 2011

Oskar Levander

LNGPac: A turn key solution

Auxiliary equipment
room

Tank room
All cryogenic valves
Length minimized

29

Wrtsil

27 September 2011

Oskar Levander

LNGPac

30

Wrtsil

27 September 2011

Oskar Levander

LNG storage
Storage volume (Relative)
4,5
Volume relative to MDO in DE

4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0,0
Diesel

Fuel

31

Wrtsil

Tank

27 September 2011

LNG (10bar)

Tank Room

Oskar Levander

Conventional tank location

32

Wrtsil

27 September 2011

Oskar Levander

LNG tanks located outside

The LNG tanks can be located outside

Does not take up space inside ship
Good ventilation
No ventilation casing needed
trough accommodation
Visible location for good PR

33

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Oskar Levander

LNG storage in trailers

34

Wrtsil

27 September 2011

Oskar Levander

LNG distribution chain

LNG logistics is a key

question for introduction
of LNG as a marine fuel

LNG Terminal

LNG Feeder

LNG Container feeder

35

Wrtsil

27 September 2011

LNG Ferry

Oskar Levander

LNG Ro-Lo

LNG Tug

Marine LNG terminals

Existing or
under construction

Proposed
As per September 2009
36

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27 September 2011

Oskar Levander

Bunkering from LNG truck

37

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27 September 2011

Oskar Levander

LNG bunker barge/tanker

38

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27 September 2011

Oskar Levander

LNG barge carrier operation principle

39

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27 September 2011

Oskar Levander

LNG barge carrier operation principle

40

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27 September 2011

Oskar Levander

LNG distribution

DISTRIBUTION

NG pipe line

Large scale LNG liquefaction plant

/ LNG import terminal

Local LNG
liquefaction plant
Local distribution
LNG terminal

PORT

LNG

LNG tank in port

Small ships

41

Wrtsil

27 September 2011

LNG tank on barge

Small & large ships

Oskar Levander

Total Concept Optimization

Wrtsil engineers solutions for LNG delivery, storage, transportation and

utilization onboard.

42

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27 September 2011

Oskar Levander

RORO CONCEPT FOR ECA

43

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27 September 2011

Oskar Levander

RoRo trends

44

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27 September 2011

Oskar Levander

RoRo trends
Growing capacity
Efficiency of scale

Slowing down
Reducing fuel costs

Flexible cargo intake

Designed for operation inside ECA areas

45

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27 September 2011

Oskar Levander

RoRo concept
RoRo vessel for European routes in ECA
Operation area: European SECA area
RoRo cargos
Double stack containers on main deck
Trailers and mafis on upper deck and in lower hold
Containers on upper deck

Focus on environmental and economical performance

Operation inside SECA area
IMO tier III NOx compliant

46

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27 September 2011

Oskar Levander

RoRo main particulars

47

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Size
Length
Length, bp
Beam, wl
Draft (design)
Depth, main deck
Speed, service
Lane meters
Deadweight (desgin)
Propulsion power
Aux power
Drivers

27 September 2011

Oskar Levander

22 000
190.0
180.0
26.6
6.5
8.3
~19
2 800
10 500
10 800 11 400
~2 100
12

GT
m
m
m
m
m
knots (incl. 15% SM)
m
tons
kW (installed)
kW (installed)
pax

Propulsion

Single screw
Simple and well proven
Good ice performance
Low cost
Energopac rudder

48

Wrtsil

27 September 2011

Oskar Levander

Machinery alternatives for comparison

1. MGO
Operates on MGO
SCR to reduce NOx to tier III limit
MDO HFO

2. HFO + Scrubber
Operates on HFO
Scrubber removes SOx
SCR to reduce NOx to tier III limit
MDO HFO

3. DF - LNG
Operates on LNG
No exhaust cleaning needed
MDO
49

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Oskar Levander

LNG

MGO
Installed propulsion power:
Installed aux power:

10.8 MW
2.1 MW

SCR needed for IMO

tier III compliance

SCR

SCR

SCR
Auxpac 1 050 kW

9L46F

EnergoPac
rudder

10 800 kW
GEAR

6L20

Auxpac 1 050 kW
9L46F
6L20

PTO
3 MW

MSB
1 MW

2 x 1 MW

MDO

50

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Oskar Levander

HFO + Scrubber
Installed propulsion power:
Installed aux power:

10.8 MW
2.1 MW

SCRUBBER

SCR needed for IMO

tier III compliance

SCR

SCR

SCR
Auxpac 1 050 kW

EnergoPac
rudder

10 800 kW
GEAR

6L20

Auxpac 1 050 kW
9L46F
6L20

PTO
3 MW

MSB
1 MW

2 x 1 MW

MDO

51

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Oskar Levander

HFO

Marine Fresh Water Scrubber System

Exhaust
Gas

Closed loop works with

freshwater, to which
NaOH is added for the
neutralization of SOx.

CLOSED LOOP
=
Zero discharge
in enclosed area

pH

NaOH unit
pH

Fresh water

Scrubber

Water Treatment

Cooling
Holding tank
Process tank

Seawater

52

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Oskar Levander

Sludge tank

Containerships VII - scrubber installation

53

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Oskar Levander

DF - LNG
Installed propulsion power:
Installed aux power:

11.4 MW
2.1 MW

6L20DF
1 056 kW
EnergoPac
rudder

11 400 kW
6L20DF

GEAR

12V50DF
6L20DF

PTO
3 MW

6L20DF
1 056 kW

MSB
1 MW

2 x 1 MW

MDO

54

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Oskar Levander

LNG

LNG storage in trailers

3 x LNG trailers = 150 m3 of LNG

55

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Oskar Levander

LNG tank capacity (LNG trucks on deck)

Target for autonomy
Daily consumption (acc. to profile)

19 tons

Total consumption

38 tons
84 m3

+ 15% Margin

+ 13 m3

Total tank capacity demand

97 m3

Volume capacity of one truck

50 m3

56

2 days

Wrtsil

Two LNG trucks loaded every second day

27 September 2011

Oskar Levander

LNG storage in trailer

57

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Oskar Levander

Assumed fuel prices

USD/ton

EUR/ton

USD/MBtu

HFO

635

455

16.5

MGO

950

680

23.4

LNG

740

530

16.0

For reference: NG market price in US: <5 $/MBTU

Source: www.bunkerworld.com (September 2011), LNG price estimated

1 EUR = 1.4 USD

58

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Oskar Levander

Operation profile
60%

Running hours

50%

40%

30%

20%

10%

0%

Port

Man

12,0
Operation mode

59

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Oskar Levander

18,5

Annual fuel consumption and cost (relative)

Energy consumption

120 %

Fuel cost

105,4 %
100,0 %

100,6 %

100,0 %

100 %
77,1 %
80 %

68,8 %

60 %

40 %

20 %

0%
MGO

60

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Oskar Levander

HFO + Scrubber

LNG

Annual fuel, lube oil and consumables cost (k)

10 years
6% interest

6.000

Senitec
chemicals

5.000

Fresh Water
4.000

NaOH
3.000

Urea
Lube oil

2.000
Fuel
1.000

0
MGO

61

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HFO + Scrubber

Oskar Levander

LNG

Machinery Investment cost

12.000
Scrubbers

Machinery first cost

10.000

SCR
Fuel system (LNG
tank etc.)

8.000

HFO system

6.000
Steering
4.000

Propulsion train
Engines

2.000

Propulsion engine
0
MGO

62

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Oskar Levander

HFO + Scrubber

LNG

Annual machinery cost

8000
Scrubber operating
costs (NaOH + FW +
Senitec Chem)

7000

Annual machinery related cost [kEUR]

SCR operating costs

6000

Maintenance costs

5000
4000

Lubrication oil costs

3000
Fuel costs

2000
Annual capital costs
1000
0
MGO

63

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Oskar Levander

HFO + Scrubber

LNG

Concept payback time (compared to MGO)

3,5

Payback Time [Years]

2,5

1,5

0,5

0
MGO

64

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Oskar Levander

HFO + Scrubber

LNG

Net present value (NPV) 10 years of operation

12000

Net Present Value [kEUR]

10000

8000

6000

4000

2000

0
MGO

65

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Oskar Levander

HFO + Scrubber

LNG

Exhaust emissions
CO2

NOx

SOx

120 %

100 %

80 %

60 %

40 %

20 %

0%
HFO - IMO tier II

REF. outside ECA

66

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MGO

HFO + Scrubber

LNG

Inside ECA, IMO tier III compliant

IMO Energy Efficiency Design Index (EEDI)

67

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EEDI
25

20

15

10

0
MGO

68

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HFO + Scrubber

Oskar Levander

LNG

Operating part time in SECA

69

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Oskar Levander

Machinery alternatives for comparison part time in ECA

1. MGO - HFO
Operates on MGO inside SECA
and HFO outside SECA
SCR used only in port and inside NECA
MDO HFO

2. HFO + Scrubber
Operates on HFO
Scrubber only used inside SECA
SCR used only in port and inside NECA
MDO HFO

3. DF - LNG
Operates on LNG all the time
No exhaust cleaning needed
MDO
70

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Oskar Levander

LNG

Annual fuel costs part time in ECA

Inside ECA

Outside ECA
33%

Annual costs [k]

67%

100%

6.000

6.000

5.000

5.000

4.000

4.000

3.000

3.000

2.000

2.000

1.000

1.000

0
HFO - MGO

HFO + Scrubber

DF-LNG

HFO - MGO

HFO + Scrubber

DF-LNG

33%

Annual costs [k]

67%

6.000

6.000

5.000

5.000

4.000

4.000

3.000

3.000

2.000

2.000

1.000

1.000

0
HFO - MGO

71

Wrtsil

100%

27 September 2011

HFO + Scrubber

Oskar Levander

DF-LNG

HFO - MGO

HFO + Scrubber

DF-LNG

Annual costs part time in ECA

Inside ECA

Outside ECA
33%

Annual costs [k]

67%

100%

8.000

8.000

6.000

6.000

4.000

4.000

SCR operating costs

Scrubber operating
costs
Maintenance costs
Lubrication oil costs

2.000

2.000

0
HFO - MGO

HFO +
Scrubber

DF-LNG

Fuel costs
Annual capital costs

HFO - MGO

HFO +
Scrubber

DF-LNG

33%

Annual costs [k]

67%

8.000

8.000

6.000

6.000

4.000

4.000

2.000

2.000

SCR operating costs

Scrubber operating
costs
Maintenance costs
Lubrication oil costs

Wrtsil

Fuel costs
Annual capital costs

0
HFO - MGO

72

100%

27 September 2011

HFO +
Scrubber

Oskar Levander

DF-LNG

HFO - MGO

HFO +
Scrubber

DF-LNG

Conclusions

DF engines a well proven technology

DF engines running on LNG has great potential
Best NPV
Lowest emissions
Short payback time

73

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Oskar Levander