EGCSA H A NDBOOK 2012 A practical guide to exhaust gas cleaning systems for the maritime industry EGCSA Handbook 2012 Exhaust Gas Cleaning Systems are a highly effective solution to the challenges of IMO MARPOL Annex VI air pollution regulations and the added complexities of regional and national emissions legislation. It is crucial that ship owners and operators fully understand their options for compliance. To aid decision making this guide contains a wealth of information, including: • The impact of emissions, current and future regulation and the IMO Guidelines for Exhaust Gas Cleaning Systems • Types of Exhaust Gas Cleaning System for SOx, PM and NOx, including system configuration and installation, materials of construction and compliance instrumentation • Scrubbing processes, dry chemical treatment and washwater handling • Comprehensive details of commercially available systems from EGCSA members As exhaust gas cleaning technologies and legislation evolve, it is intended to further update this publication to keep pace with developments and EGCSA encourages all with an interest in this business critical area to take full advantage of each new edition as it is released. Price: £105.00 Contents CONTENTS................................................................ 1 5.1.1 Wet scrubbers.................................................. 58 LIST OF FIGURES......................................................... 2 5.1.2 Dry scrubbers................................................... 63 LIST OF INFO BOXES................................................... 3 6 TREATMENT PROCESSES - NOx.................................64 LIST OF TABLES........................................................... 3 6.1 Selective Catalytic Reduction (SCR).......................... 64 FOREWORD............................................................... 4 6.1.1 SCR control...................................................... 65 INTRODUCTION......................................................... 5 6.1.2 Oxidation catalysts............................................ 67 1. AIR POLLUTION - COMBUSTION............................... 6 6.2 Exhaust Gas Recirculation (EGR).............................. 67 1.1 Ship Emissions....................................................... 7 7. EGC SYSTEMS AND VENDORS................................71 1.1.1 MARPOL Annex VI – regulation 14......................... 8 7.1 Performance Overview.......................................... 72 1.1.2 Gaseous emissions............................................ 10 7.1.1 SOx................................................................ 73 1.1.3 Primary particulates............................................ 11 7.1.2 Particulate matter............................................... 73 1.1.4 Secondary particulates....................................... 14 7.1.3 NOx............................................................... 75 2. REGULATIONS AND GUIDELINES.............................15 7.1.4 CO2............................................................... 77 2.1 International Maritime Organization (IMO)................ 15 7.1.5 Instrumentation – gaseous emissions...................... 77 2.1.1 Compliance by Exhaust Gas Cleaning.................. 16 7.2 Mechanical Details............................................... 81 2.2 Regional Emissions Control..................................... 17 7.2.1 Consumption and flow....................................... 81 2.2.1 Europe............................................................ 17 7.2.2 Size and position.............................................. 82 2.2.2 USA and Canada............................................. 19 7.3 Experience, Testing and Approvals........................... 86 2.3 Future Emission Limits............................................. 21 7.4 Installation and after-care....................................... 87 2.3.1 Carbon Monoxide (CO)..................................... 21 7.5 Commercial Information......................................... 88 2.3.2 Hydrocarbons (HC)........................................... 22 APPENDIX 1 Information and Data Summary - 2.3.3 Particulate Matter (PM)....................................... 22 EGC Systems and Vendors............................................92 2.3.3.1 Black Carbon (BC)......................................... 22 APPENDIX 2 Resolution MEPC.184(59) 3. GUIDELINES FOR EXHAUST GAS 2009 Guidelines for Exhaust Gas Cleaning Systems........104 CLEANING SYSTEMS (EGCS).......................................23 3.1 Introduction......................................................... 23 APPENDIX 3 Emission Control Area 3.2 Overview........................................................... 24 Geographic Definitions..............................................116 3.3 Scheme A........................................................... 25 A3.1 MARPOL Annex VI Regulation 14 - Sulphur Oxides 3.4 Scheme B........................................................... 26 (SOx) and Particulate Matter - Emission Control Areas 3.5 Washwater......................................................... 27 Geographic Definitions.............................................. 116 3.5.1 pH................................................................. 28 A3.1.1 Baltic Sea.................................................... 116 3.5.2 Polycyclic Aromatic Hydrocarbons (PAH)................ 29 A3.1.2 North Sea.................................................... 116 3.5.2.1 PAH measurement........................................... 30 A3.1.3 North America.............................................. 116 3.5.3 Turbidity........................................................... 31 A3.1.4 U.S. Caribbean............................................ 116 3.5.4 Nitrate............................................................ 31 A3.1.5 New areas.................................................. 116 3.5.5 Washwater additives and treatments..................... 34 A3.1.6 NOx Emission Control Areas........................... 116 3.5.6 Washwater treatment plant residue....................... 34 APPENDIX 4 NOx Emission Limits and Schedule 4. TREATMENT PROCESSES - SOx................................35 for Reduction............................................................118 4.1 Wet Exhaust Gas Cleaning Systems......................... 35 A4.1 MARPOL Annex VI Regulation 13 – 4.1.1 Removal of sulphur oxides - seawater.................... 40 Nitrogen Oxides (NOx)............................................. 118 4.1.2 Removal of sulphur oxides - freshwater A4.1.1 Tier I........................................................... 118 with chemical addition................................................ 40 A4.1.2 Tier II.......................................................... 118 4.1.3 Water quality at Exhaust Gas Cleaning System inlet.....42 A4.1.3 Tier III.......................................................... 118 4.1.4 Washwater treatment......................................... 47 APPENDIX 5 USCG Marine Safety Alert.......................119 4.1.4.1 pH.............................................................. 47 A5.1 Fuel Switching Safety........................................ 119 4.1.4.2 Particulate matter and oil.................................. 47 4.1.5 Effects on seawater composition........................... 49 APPENDIX 6 U.S. EPA 16 Priority Pollutants...................120 4.1.5.1 Sulphate....................................................... 49 4.1.5.2 Oxygen........................................................ 49 APPENDIX 7 Installation of a Multi-Stream, 4.1.5.3 Acidification.................................................. 49 Hybrid EGCS - M.V. Balder........................................124 4.1.6 Materials of construction..................................... 50 REFERENCES...........................................................136 4.1.6.1 Exhaust gas cleaning system............................. 50 4.1.6.2 Exhaust duct.................................................. 51 GLOSSARY OF TERMS, 4.2 Dry Exhaust Gas Cleaning Systems.......................... 52 FORMULAE & ABBREVIATIONS........................................ 140 4.2.1 Supply and disposal of consumables..................... 55 ADDENDA/CORRIGENDA..........................................145 5. EXHAUST GAS CLEANING TECHNOLOGIES..............56 3.5.2.1.PAH measurement, 5.1 Removal methods................................................. 56 addendum – phenanthrene equivalents......................... 145 1 List of Figures List of Info Boxes List of Tables Figure 1: The link between atmospheric sulphur Figure 30: Flow schematic – dry Exhaust Gas Info Box 1: Article 4c of Directive 2005/33/EC ......... 18 Table 1: Gaseous pollutants dioxide concentration and human mortality ....... 6 Cleaning System combined with SCR ............ 54 and climate change agents ............................. 10 Info Box 2: EC - new sulphur standard for shipping ....... 18 Figure 2: Sulphur oxide deposition without exhaust Figure 31: Particle trapping process ............................. 58 Table 2: U.S. EPA Category 3 Info Box 3: Flue gas desulphurisation with gas cleaning ............................................... 8 engine emission limits .................................... 21 Figure 32: Wet scrubber packed bed material ............... 59 water in land based applications ............... 24 Figure 3: PAH analysis, gasoline, diesel, propane .......... 9 Table 3: Fuel oil sulphur limits recorded in Figure 33: Wet