Measurement of Emissions from the Main Propulsion Engine (MAN B&W 11K90MC-C) on a Panamax Class Container Ship Final Report (April 2, 2009) Contract # 05-412 Prepared for: California Air Resources Board 1001 I Street, Sacramento, CA 95814 Authors: Dr. J. W. Miller Mr. Harshit Agrawal Mr. Bill Welch University of California, Riverside College of Engineering-Center for Environmental Research and Technology Riverside, CA 92521 Emissions from the Main Propulsion Engine on a Pamamax Class Ship Disclaimer This report was prepared as the result of work sponsored by the California Air Resources Board (CARB) and as such does not necessarily represent the views of CARB or its employees. CARB, its employees, contractors and subcontractors make no warrant, express or implied, and assume no legal liability for the information in this report; nor does any party represent that the uses of this information will not infringe upon privately owned rights. This report has neither been approved nor disapproved by CARB and CARB has not passed upon the accuracy or adequacy of the information in this report. 2 Emissions from the Main Propulsion Engine on a Pamamax Class Ship Acknowledgements The authors express appreciation to the following associates who contributed much to the success of the project and the furtherance of knowledge of emissions from ocean going vessels operating in waters near California. We very much appreciated the financial support of the CARB throughout the project, their help in planning the test work and the assistance of the shipping company and the helping hands on the vessel for enabling these measurements to be integrated into their busy operating schedule. California Air Resources Board • Ms. Peggy Taricco • Ms. Bonnie Soriano • Mr. Paul Milkey 3 Emissions from the Main Propulsion Engine on a Pamamax Class Ship Table of Contents Disclaimer ---------------------------------------------------------------------------------------------2 Acknowledgements-----------------------------------------------------------------------------------3 Table of Contents-------------------------------------------------------------------------------------4 Table of Figures--------------------------------------------------------------------------------------6 Table of Tables ---------------------------------------------------------------------------------------6 Executive Summary----------------------------------------------------------------------------------7 1 Introduction-------------------------------------------------------------------------------------8 1.1 Project Objective ------------------------------------------------------------------------------ 9 2 Test Plan--------------------------------------------------------------------------------------- 10 2.1.1 Test Engine ----------------------------------------------------------------------------------------------- 10 2.2 Test Fuels---------------------------------------------------------------------------------------11 2.3 Test Cycle and Conditions ------------------------------------------------------------------11 2.3.1 Operating Conditions for Measuring Emissions from the Main Engine------------------------ 12 2.3.2 Calculation of Emission Factor------------------------------------------------------------------------ 12 2.3.3 Calculation of the Exhaust Flow Rate---------------------------------------------------------------- 13 3 Results------------------------------------------------------------------------------------------ 14 3.1 Fuel Properties --------------------------------------------------------------------------------14 3.2 Sampling Ports--------------------------------------------------------------------------------14 3.3 Primary Gaseous Emissions ----------------------------------------------------------------15 3.3.1 Main Engine Gaseous Emissions --------------------------------------------------------------------- 15 3.4 Particulate Matter (PM) Emissions -------------------------------------------------------16 3.4.1 PM Mass Emissions ------------------------------------------------------------------------------------- 16 3.5 Composite Particulate Matter Emissions ------------------------------------------------18 3.5.1 Elemental and Organic Carbon------------------------------------------------------------------------ 18 3.5.2 Emissions of Sulfate------------------------------------------------------------------------------------- 19 3.5.3 Quality Check for Conservation of PM Mass Emissions ----------------------------------------- 19 4 Findings and Recommendations ---------------------------------------------------------- 21 4.1 Findings ----------------------------------------------------------------------------------------21 4.2 Recommendations ----------------------------------------------------------------------------22 Appendix A ------------------------------------------------------------------------------------------ 23 A.1 Certification Emission Test Protocol for Main Engines------------------------------------------------ 23 A.2 Measuring Gaseous and PM Emissions from Marine Diesel Engines ------------------24 A.2.1 Measuring the Gaseous Emissions ---------------------------------------------------------------------- 26 A.2.2 Measuring the Particulate Matter (PM) Emissions --------------------------------------------------- 27 4 Emissions from the Main Propulsion Engine on a Pamamax Class Ship A.3 Quality Control/Quality Assurance (QC/QA)------------------------------------------------------------ 28 Appendix B ------------------------------------------------------------------------------------------ 30 B.1 Detailed specifications for the Panamax Class Vessel -------------------------------------30 B.2 Detailed specifications for the K90MC Engines --------------------------------------------30 Appendix C – Test Data and Calculations----------------------------------------------------- 32 C.1 Detailed Engine Operational Results ---------------------------------------------------------32 C.2 Emissions Sampling System Dilution Ratios ------------------------------------------------33 C.3 ISO Correction Factors for Temperature and Humidity ---------------------------------34 C.4 Gaseous Emissions Data and Calculations---------------------------------------------------35 C.5 Particulate Matter Emissions Data and Calculations -------------------------------------37 C.6 Criteria Pollutant Summary Results and Statistics ----------------------------------------39 C.7 Fuel Analyses--------------------------------------------------------------------------------------40 C.8 Gas Analyzer Calibrations----------------------------------------------------------------------42 5 Emissions from the Main Propulsion Engine on a Pamamax Class Ship Table of Figures Figure 1-1 Trends for Various Port-Related Emissions (tons/day).............................. 8 Figure 2-1 Picture of the Fuel Injectors on an Engine from the 11K90MC-C Series ........................................................................................................................................... 10 Figure 3-1 Picture of the Partial Dilution Tunnel Direct Connection with the Main Exhaust............................................................................................................................. 15 Figure 2 Emission Factor (g/kW-hr) for Different Gases from the Main Engine as a Function of Load * Note CO 2 scale ............................................................................... 16 Figure 3 Emission Factor (g/kW-hr) for Particulate Matter from the Main Engine as a Function of Load.......................................................................................................... 17 Figure 4 Emission Factors in g/kW-hr for the Elemental & Organic Carbon PM fractions ........................................................................................................................... 18 Figure 5 Figure of the Sulfate Emissions vs. Engine Load.......................................... 19 Figure 6 Comparative Plots of Total PM Emissions with Composite PM Emissions ........................................................................................................................................... 21 Figure A-1 Partial Flow Dilution System with Single Venturi, Concentration Measurement and Fractional Sampling........................................................................ 24 Figure A-2 Field Processing Unit for Purifying Dilution Air in Transport Case ..... 25 Figure A-3 In-field Illustration of Continuous Gas Analyzer and Computer for Data Logging............................................................................................................................. 26 Table of Tables Table 2-1 Main Engine Test Schedule........................................................................... 11 Table 3-1 Selected Properties of the Fuel Used on the Vessel..................................... 14 Table 3-2 Emission Factor of Different Gases for Main Engine ................................ 16 Table 3-3 Numeric PM Emission Factors in g/kW-hr & Statistics ............................ 17 Table 3-4 Sulfate Emissions (g/kW-hr) for the Main Engine ..................................... 19 Table 3-5 Comparison of PM Emission Factors with EC+OC+ Hydrated Sulfate Emission Factors for Main Engine................................................................................ 20 Table 4-1Emission Factors of Criteria Pollutants for Main Engine .........................