+ LNG … A Better Way to Cold Iron - aapa-ports.org · appendages, and propeller are minimized...
Transcript of + LNG … A Better Way to Cold Iron - aapa-ports.org · appendages, and propeller are minimized...
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Vessel Efficiency Improvements for
Reducing CO2 Footprint
+ LNG … A Better Way to Cold Iron
American Association Port Authorities
Harbors, Navigation, & Environmental Seminar
and Green Port AmericasCharleston, SC
4 - 6 May 2010
John F. Hatley PE
Americas Vice President Ship Power
Wartsila North America, Inc.
www.wartsila.com
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Not just Engines
Wartsila Power Range 800 - 80,000 kW
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But also … Matched Propulsion Systems
Wartsila propels Wet End as well
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+ Wartsila Environmental
Wartsila SCR in 100+ Vessels
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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Environment Drives Ship Design
Emission reductionNOX emissions
SOX emissions
SECA areas
North American ECA
Climate changeGreenhouse gases
Focus on CO2 emissions
Fuel costScarcity escalates prices
Tighter Sulphur requirements
Good Stewards today for future generations
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US / Canada Emission Control Area “ ECA ”
US & Canada
Submitted IMO 27 March 2009
200 Nautical Miles off Coastlines
Exclusive Economic Zone EEZ
MEPC 59
Committee recommended 17 July 2009
IMO
Anticipate Adoption March 2010
History “ SECA”
Exclusively Control SOx
1st Baltic Sea enforced May 2005
2nd North Sea November 2006
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Greenhouse Gas
CO2 emission reduction
Reduce power demand
Ship and propulsion design
Operation profile
Improve efficiency
Propulsion optimisation
Engine technology
Waste energy recovery
Use alternative fuels
Lower carbon content fuels
Fundamental shifts in vessels; why, what, how
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Vessel Energy Efficiency
Energy in fuel
100%
45.3%
Brake power
46.5%
Heat and
losses
53.5% 42.7%
Transmission
losses
1.2%
Utilised exhaust
heat recovery
2.8%
Utilised HT water
heat recovery
1.9%
Surplus
recoverable
exhaust heat
8.0%
Surplus recoverable
HT water heat
12.0%
Useful Energy 32.5%
Lo
sse
s a
nd
un
used
en
erg
yLosses
28.8%
30 000 gt
Estimation for
service speed mode
Electric power
4.2%
Effective power
23.6%Additional
resistance from
waves, wind
and hull fouling
3.5%
Propulsion
losses14.0%
Lo
sses a
nd
un
used
en
erg
y
9 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
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Typical Annual Costs
Manning
7%
Canal tolls &
misc
3%
Port dues
7%
Bunkers
58%
Cargo
handling
costs
1%
Capital costs
15%
Stores &
lubes
2%
Sales
1%
Insurance
1%
Repairs &
Maintenance
3%
Admin & Mgmt
2%
15 years , 6% interest
HFO = 400 € / ton
Annual CAPEX + OPEX = 13,000 K € … Fuel Dominates 2/3 Costs
10 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
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Efficiency Areas
Technologies
Ship design
Propulsion
Machinery
Operation &
Maintenance
11 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
Engineered & operational integration of these principles yields
optimal overall ship efficiency
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AIR LUBRICATION
DELTA TUNING
OPTIMUM MAIN
DIMENSIONS
ENERGOPACK
HULL CLEANINGWIND POWER
VOYAGER PLANNING
– WEATHER ROUTING
Tanker, Bulker Efficiency Improvements
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LIGHTWEIGHT
CONSTRUCTION
PROPELLER
BLADE DESIGN
HULL SURFACE
– HULL COATING
BOW THRUSTER
SCALLOPS / GRIDS
WASTE HEAT
RECOVERY
SHIP SPEED
REDUCTION
EFFICIENCY
OF SCALE
Container Efficiency Improvements
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HYBRID AUXILIARY
POWER GENERATION
CONDITION BASED
MAINTENANCE (CBM)
SOLAR
POWER
ENERGY SAVING
OPERATION AWARENESS
REDUCE
BALLAST
VESSEL TRIM
ADJUSTMENT
Ro-Ro Efficiency Improvements
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ENERGY SAVING
LIGHTNING
PROPULSION
CONCEPTS – CRP
CODED
MACHINERY
FUEL TYPE
– LNG
TURNAROUND
TIME IN PORT
INTERCEPTOR
TRIM PLANES
COOLING WATER PUMPS,
SPEED CONTROL
Ferry Efficiency Improvements
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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Symbols
17 © Wärtsilä 11 May 2010 Presentation name / Author
< 4%
Ship types for which the
energy efficiency
improvement suits best
Retrofit Measures likely
for existing vessels
Operational measuresMethods suited for
new buildings
Potential upper range of vessel overall annual
fuel savings, not a specific power mode
Payback timeframe
Short < 1 year to Long > 15 years
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Ducktail Waterline Extension
18 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 7%
Ducktail reduces wetted
transom and lengthens
effective waterline
resulting in reduced hull
resistance
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Optimum Hull Dimensions
19 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 9%
Finding optimum length and hull
fullness ratio Cb exponentially
impacts ship resistance
Large Length to Beam L/B ratio
means ship has smooth lines,
narrow entry and exit, brings
benefit of lower wave making
resistance
High block coefficient Cb blunts
hull lines and negatively
increases resistance.
A vessel with 10-15% extra length may achieve powering reduction
near 10%.
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20 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
Scale Efficiency
Larger ships usually achieve greater transport efficiency
Regression analysis shows 10% larger ship achieves a
4 - 5% higher transport efficiency all other things equal
< 4%
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Propeller Hull Interaction optimization
21 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
Computer advances in
Hydrodynamic design bring
improved interactions between
hull and propeller
Negative resistance of
propeller water acceleration
actions amongst hull,
appendages, and propeller are
minimized improving
performance
< 4%
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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Interceptor trim planes
23 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 4%
The transom mounted
interceptor plate deflects
flow downward across
stern which creates lift
and reduces hull
resistance reducing
power demand
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Shaft line arrangement
24 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 2%
Streamlining shaft lines and brackets lowers flow
disturbances = reduced resistance.
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Pulling thrusters
25 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 10%
Pulling steerable thrusters combined with center Contra
Rotating Propeller or Wing Thrusters improve propulsion
efficiency.
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Advanced propeller blade sections
26 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 2%
Advanced
improvements in blade
sections reduces
cavitation and frictional
resistance.
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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Waste heat recovery
28 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 15%
Waste heat recovery (WHR) recovers thermal exhaust
gas energy and converts to electrical energy employing
a steam boiler and turbine alternator
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CODED machinery
29 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 4%
Combined Diesel-Electric
and Diesel-Mechanical
( CODED )machinery
provide broad range of
modal efficiency gains; at
part load electrical
efficiency benefits are
achieved while at high
power the mechanical
drive system loss
transmission losses
achieve efficiency
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LNG as fuel
30 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 4%
LNG as a fuel reduces
energy consumption
onboard
No HFO heating
Cold LNG (-162 °C)
can be utilized in
HVAC cooling to
reduce compressor
power
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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Hull cleaning
32 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 3%
Algae and marine organism hull
growth negatively increases ship
resistance
Frequent housekeeping with hull
cleaning reduces drag influence
Fuel reductions vary by ship type and
operational speeds; Tankers 3% ….. OSV 0.6%
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Hull surface coatings
Modern paint coatings
possess hard smooth
surfaces which reduce
hull friction and deter
fouling
33 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
Fuel savings vary by ship type and operational
speeds; Tankers 9% ... Ferry 3 %
< 5%
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Ship speed
34 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 23%
Speed reduction
efficiently cuts
energy consumption
Reductions
0.5 kn --> - 7% energy
- 1.0 kn --> - 11% energy
- 2.0 kn --> - 17% energy
- 3.0 kn --> - 23% energy
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Reduce ballast
Minimal ballast results
in lighter displacement
and thus lower
resistance
35 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 7%
Removing 3000 ton of permanent
ballast from a PCTC and achieving
similar stability by increased beam
0.25 m reduces propulsion power
by 8.5%
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Propeller surface finish/polishing
36 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 9%
Regular in service
polishing off
organic growth and
fouling reduces
surface roughness
on propellers
Efficiency gains up
to 10% compared
to a fouled
propeller
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Voyage planning – weather routing
37 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 10%
Updated satellite climatic data allows optimal voyage
tracks to follow best weather route
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Condition Based Maintenance (CBM)
38 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 5%
Satellite communication allows
real time remote monitoring
trend analysis
smart systematic diagnosis
expert personnel observation
Main benefits
lower fuel consumption
lower emissions
longer interval between overhauls
higher reliability
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Energy saving lighting
39 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 1%
Use efficient lighting wherever possible and
optimized lighting use reduces electricity
and air conditioning demand
Fuel consumption
saving for a vessel:
~1%
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Energy saving operational awareness
40 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 10%
A culture of fuel saving and reward or bonus system
based on fuel savings encourages internal
competition amongst vessels in fleet
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Turnaround time in port
41 © Wärtsilä 11 May 2010 Oskar Levander / Ship Power R&D
< 10%
Quicker port turnaround time
allows transit speed reduction
while maintaining schedules
Turnaround time is reduced by
improved maneuvering
performance or enhancing cargo
flows through innovative ship
and terminal design
Reducing ferry port time:
Port time Energy
2 h --> 100%
-10min --> 97%
-20min --> 93%
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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Natural gas … mostly methane (CH4)
Methane has highest hydrogen content energy
of any fossil fuel
Carbon to hydrogen ratio 1 / 4 (gasoline: 1 / 2,25)
Natural gas is:
Non-toxic
Colourless
Odourless
Lighter than air
What is natural gas?
Methane (CH4)H
H
H
H
C Ethane (C2H6)
Natural Gas has least Carbon content = Low CO2 Emissions
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Low Natural Gas Emissions
25-30% lower CO2
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
50% lower PM Particulates
Particulates vary across operating range
No visible smoke
No sludge deposits extends engine life and time between
overhauls achieving maintenance savings
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US
D/M
Btu
LNG Japan CIF [USD/MBtu]
NG Henry hub [USD/MBtu]
HFO 380cst Rotterdam [USD/MBtu]
MGO Rotterdam [USD/MBtu]
Win Win : Emissions Reduction & OPEX Savings
Sources: www.lngoneworld.com, www.bunkerworld.com, LR Fairplay
LNG
MGO
Historical ~ 40% FUEL PRICE BENEFIT
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Agenda
Efficiency Technologies & Energy Savings
Evolving Developments
Ship Design
Propulsion
Machinery
Operations & Maintenance
Why Clean Natural Gas
LNG Improves Cold Ironing
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10 July 2009
San Diego approves $7.6 M for giant electrical plugs… so
vessels can shut down diesel generators while in port.
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Definition Cold Ironing
Source: http://en.wikipedia.org/wiki/Cold_Ironing
Cold ironing at berth substitution of “preferred” shore power over
traditional undesirable ship genset fuels misses LNG benefits !
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Ship Port Transit Steps
Sources:
1. http://www.oldsaltblog.com/tag/container-ship
2. http://www.ports.co.za/images/MAE
RSK-BOSTON.jpg
3. news.xinhuanet.com/.../09/content_
11154169.htm
4. http://www.ports.co.za/images/MAE
RSK-BOSTON.jpg
5. flickr.com/photos/77759596@N00/2063547505 /
Ship approaches coastline
Ship maneuvers to pier
Cargo load / unloading ops
Ship departs berth
Ship heads to sea
Suboptimal Cold ironing focus at berth …
is there a better approach?
Cold Ironing limits
emissions only during
dockside cargo efforts
while missing majority
of vessel activities
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LNG Onboard Gensets
LNG auxiliary gen set electrical power for container vessels
Onboard units power vessel’s entire coastwise transit & port stay
Economically feasible
Significant emissions reduction
Available Technology
50 © Wärtsilä 11 May 2010 Wartsila 11 November 2009 John Hatley WNA SP
Port Electricity Production Cost
0
2
4
6
8
10
12
14
Shore power MGO MDO LNG
¢ / k
Wh
LNG = Superior solution to coastal and port emissions over
dockside Cold Ironing… best duration, costs, stakeholder needs
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LNG Storage Possibilities
Topside ISO Containers or permanent below deck LNG fuel tankage
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LNG Gensets Case Study
Containership
Length over all 322.34 m
Breadth 40.00 m
Draught 14.00 m
Deadweight 84 500 ton
Main engine Wärtsilä 11RT-flex96C
Propulsion power 62 920 kW
Speed (trial) 25.5 kn
Cargo capacity 7 300 TEU
Reefer plugs 1 300 FEU
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Trans-Pacific Voyage Route
Los Angeles – Oakland – Dalian – Busan – Nagoya – Yokohama – Los Angeles
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Operating US west coast
Coastal Zone … fuel with very low sulfur to
reduce S0x … was 24 miles soon 200 miles ECA
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Container Cargo Electrical Load
1,300 refrigerated cargo containers
consume high electrical power to
maintain cold storage.
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
Port Manoeuvring Cruise
kW
Large electrical cargo loads demand > 8,000 kW ( 10,800 HP )
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Operating Profile LNG Consumption
Ton / hour hours tons
Cargo Loading & Unloading 1.5 138 207.0
Maneouvering 2.1 6 12.6
Coastwise slow transit with
clean low sulphur diesel*
1.6 10 16.0
Run Time
per round tripConsumption
per round trip
LNG
consumption
2 Fixed tanks @ 190 m3 ... Bunker twice ( 1.4 x ) each voyage
236 Tons LNG = 523 m3
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Fixed LNG Tankage
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Or Containerized Above Deck LNG Storage
Topside ISO Containers provide flexibility and capacity
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LNG consumption – West Coast Ports
Ton / hour hours tons
Cargo Loading & Un-
loading
1.5 58 87.0
Maneuvering 2.1 2 4.2
Slow steaming
coastwise
1.6 10 16.0
108
Tankage Need 8 units 40ft ISO LNG containers @ 31.5 m3 = 240 m3
Los Angeles and
Oakland Ports
108 tons LNG = 240 m3
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Study Fuel Prices
USD/ton EUR/ton USD/MBtu
LSHFO 440 335 11.4
MDO 680 515 16.8
MGO 740 565 18.2
LNG 510 390 11.0
60 © Wärtsilä 11 May 2010 Wartsila 11 November 2009 John Hatley WNA SP
Source: www.bunkerworld.com (Rotterdam Oct 2008), LNG price estimated
1 EUR = 1.31 USD
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Ship Operating Profile
0%
20%
40%
60%
80%
Loading &
unloading
Maneuvering Slow Slow with
clean fuel*
Service
speed
Op
era
tin
g h
ou
rs %
Clean fuel is to be used in aux engines in all these time phases
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Annual Aux Gen Set Fuel Cost
0
200
400
600
800
1,000
1,200
1,400
1,600
1,800
2,000
Diesel DF Diesel with shore
power
kE
UR
- 700 k €
- 1 600 k €
SHORE
POWER
COST
LNG Lowest emissions & Annual Cost Savings 700 K €
Shore Power similar costs but hosts emissions achievement short fall
LNG Win + Win = Emissions & Cost Reduction
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Auxiliary Engine CAPEX
0
2,000
4,000
6,000
8,000
10,000
Diesel DF Diesel with shore
power
k
EU
R
Investment cost for aux engines includes
Engines + Generators … LNG System … Shore Power Connection
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Annual CAPEX + OPEX “All In” Costs
0
500
1,000
1,500
2,000
2,500
3,000
Diesel DF Diesel with shore
power**
k
EU
R
Shore power
Investment
Fuel
** Shore power
rate 0.09 $ / kWh
- 320 k € - 170 k €
LNG Genset Financial Payback 15 Years at 6 %
LNG Genset Emissions Environment Payback immediate
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LNG Emissions Reductions
0%
20%
40%
60%
80%
100%
120%
Diesel DF Diesel with shore power
CO2 NOx SOx
17 % 80 %
Po
we
r p
lan
t*
LNG DF Reductions = 1900 Tons CO2 190 Ton NOx 7 Ton SOx
Shore Power Plant … uncertain ????
50 %
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Shoreside Cold Ironing
Source: http://en.wikipedia.org/wiki/Cold_Ironing
Several shore-side linkages bring power to ship from
land … multiple interfaces pose match challenges
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Shipboard Electrical Systems
Several different ship electrical systems complicate
smooth integration with cold ironing port infrastructure
Source: http://en.wikipedia.org/wiki/Cold_Ironing
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Land Electrical Systems
Utility frequencies miss ship needs… result employ shore
transformers @ 3% inefficiency = costly CO2 increase
Source: http://crosstree.info/Documents/ColdIroning.pdf
Fuel- Energy in Ports: Maritime Industry Cold Ironing An Overview, Capt. Kohli, Cross Tree Techno-visors
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What size connection Plug ?
Variety of ships shore-bus connection types present “plug &
play” challenges
Source: http://crosstree.info/Documents/ColdIroning.pdf Fuel- Energy in Ports: Maritime Industry Cold Ironing An Overview, Capt. Kohli, Cross Tree Techno-visors
Source:http://www.coldironing.us/unitedstates
coldironing.htm
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Scorecard: Port Cold Iron Vs. LNG Ship Gensets
•Source: www.flickr.com/.../72157614009675574/detail/
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Scorecard: Port Cold Iron Vs. LNG Ship Gensets
•Source: www.flickr.com/.../72157614009675574/detail/
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Scorecard: Port Cold Iron Vs. LNG Ship Gensets
•Source: www.flickr.com/.../72157614009675574/detail/
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Scorecard: Port Cold Iron Vs. LNG Ship Gensets
Onboard LNG Gensets superior win for environmental protection …
optimal stakeholder solution serving both Public & Shipowner
•Source: www.flickr.com/.../72157614009675574/detail/
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Conclusions
LNG provides OPEX savings and Emissions reduction in port
DF achieves portside goal of lower emissions and uniquely extends reductions to / from horizon
DF independence from port facilities eliminates many concerns and brings timely efficiencies
LNG system + DF gen setsInvestment Payback Less Than 3 years
74 © Wärtsilä 11 May 2010 Wartsila 11 November 2009 John Hatley WNA SP