This document discusses MAN Diesel & Turbo's exhaust gas recirculation (EGR) technology for reducing nitrogen oxide (NOx) emissions from ships to meet upcoming Tier III standards. It provides an overview of EGR, including the system layout, key components, control system, and initial service experience on MAN engines equipped with EGR. EGR works by recirculating a portion of exhaust gas into the engine to reduce combustion temperatures and lower NOx production. MAN has conducted successful sea trials of EGR technology and found no adverse impacts to engine components after over 700 hours of operation.

1. 2013
MAN Diesel & Turbo
MAN Diesel & Turbo
„Engineering the Future – since 1758“
• MAN B&W low speed TierIII
Technologies
• Jesper Gram
LEO8
• LEO8 – Emission Technology
Fyns Maritime Klynge
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2. Disclaimer
All data provided on the following slides is for information
purposes only, explicitly non-binding and subject to changes
without further notice.
MAN Diesel & Turbo
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3. Volkswagen Group
MAN Diesel & Turbo
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4. Organizational Structure
MAN Diesel & Turbo
Executive Board
Group Functions (Gx)
SBU
Marine Systems
SBU
Turbomachinery
SBU
Engines
SBU
After Sales
Support Functions
EL
Support Functions
Rx
Support Functions
Ex
Support Functions
Ax
BU Low Speed (L)
BU Process Industry (I)
BU Turbocharger (T)
BU PrimeServ Diesel (D)
BU Oil & Gas (O)
BU Production (W)
BU PrimeServ Turbo (S)
BU Medium Speed (M)
SBU
Power Plants
BU Power Plants (P)
Global Organization (GO)
MAN Diesel & Turbo
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5. MAN Diesel & Turbo in World Trade
50% of World Trade is powered by
MAN Diesel Engines!
MAN Diesel & Turbo
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6. Products
Engines & Marine Systems
 2-stroke and 4-stroke engines for marine
applications
 Output range from 450 kW to 83,000 kW
(Low Speed)
 Gensets from 450 kW to 11,200 kW
 Fuels: diesel, bio-fuels, heavy-fuel oil,
gas/dual fuel
 Complete propulsion packages
MAN Diesel & Turbo
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7. Licensees Overview
Licensee network
Japan
China P.R.
CSIC, Shanghai Qiyao Engine (SQE)
CSIC, Shaanxi Diesel Engine Heavy Ind. (SXD)
CSIC, Henan Diesel Engine Heavy Industry (HND)
CSIC, Wuhan Marine Machinery Plant (WMMP)
CSIC, Dalian Marine Diesel (DMD)
CSIC, Yichang Marine Diesel (YMD)
CSSC, Zhenjiang CME (ZJCME)
CSSC, Hudong Heavy Machinery (HHM)
CSSC - MES Diesel (CMD)
CSSC - Guangzhou Marine Diesel (GMD)
Dalian Locomotive & Rolling Stock Company
(DLRC)
Hangzhou Zhonggao Engine (ZGPT)
STX Dalian (STXD), STX Fushun (STXF)
Jiangsu Antai Power Machinery (JAD)
Weichai Heavy Machinery (WHM)
CSR Ziyang Locomotive (CSR)
Zhongji Hitachi Zosen Diesel Engine (ZHD)
Hefei Rong An Power Machinery (RPM)
Zhenjiang Yungpu Heavy Machinery (YungPu)
Jinan Diesel Engine Works (JDEW)
n n
n
n
n
n
n n
n n
n
n

1980
2004
2007
n 2006
1980
1989
1980
1980
2007
2011
n
n n
n
n
n
n
n n
n
n
2004
2006
2007
2007
2008
2008
2008
2008
2009
2009
n n
n n
n
1967
1984
1998
Croatia
Brodosplit
Uljanik
Adriadiesel
1911
1926
1929
1951
1964
1963
1973
Korea
Hyundai Heavy Industries
STX Heavy Industry, STX Engine
Doosan Engine
STX Enpaco
n
n n
n n
1976
1977
1983
1995
n
n
Poland
H. Cegielski Poznan
n n
1959
Russia
n
Bryansk
n
1959
Spain
n
1965
n
1995
U.S.A.
Fairbanks Morse Engine
Vietnam
n
Kirloskar
MAN Diesel & Turbo
n n n
n
n
n
n
n
n
n
Navantia
India
n Low-Speed
Kawasaki
Mitsui
Mitsubishi
Hitachi
J.F.E. Engineering
Diesel United
Niigata
n Medium-Speed
1977
 High-Speed
LEO8
n
Vinashin
n Turbocharger
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2004
n CP-Propeller
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8. Sites
Worldwide Locations (Service Centers/Hubs)
>100 global service centers/hubs in >50 countries
MAN Diesel & Turbo
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9. MAN B&W Branded Propulsion Engines
Marketshares Propulsion power
Contracting in 2011 Ships larger than 2,000 DWT/GT
31%
MAN B&W *
WAR Low
MIT Low
OTH Low
Other Eng. Types
0%
61%
1%
*) MDT Low speed engines
7%
100%=19.2 GW
Source: IHS Fairplay and LB Calculations. FMS/JSA Feb. 2012
MAN Diesel & Turbo
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10. NOx limits for large marine engines
NOx (depends on ship keel laying date):
Ship construction date
Inside NOx ECA
Outside NOx ECA
Before 2000
uncontrolled
uncontrolled
2000 to 2010
Tier I (17.0g/kWh*)
Tier I
2011 to 2015
Tier II (14.4g/kWh*)
Tier II
After 2016
Tier III (3.4g/kWh*)
Tier II
* engines with maximum rpm <130
Tier II 1st January 2011
Achieved by in-engine measures
(also globally after 2016)
Tier III
MAN Diesel & Turbo
1st January 2016
Advanced NOx reduction methods
(only in defined Emission Control Areas, ECAs)
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11. NOx limits for new engines
MAN Diesel & Turbo
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12. Emission Control Areas
Current adopted ECAs:
Baltic Sea & North Sea: SOx ECA
North America: NOx and SOx ECA (from August 2012)
US Caribbean: Nox and Sox ECA (From 2014)
Our expections on likely future new ECAs, prioritised:
1. Baltic Sea NOx ECA
2. North Sea NOx ECA
Japanese NOx ECA – no?
MAN Diesel & Turbo
Source: DNV (http://www.dnv.com/resources/reports/greener_shipping_north_america.asp)
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13. Nox reduction candidate technology
Tier III candidate technology:
WIF (Water in Fuel emulsion)
SAM (Scavenge Air Moistening)
EGR (Exhaust Gas recirculation)
SCR (Selective Catalytic Reduction)
Turbocharger
compressor outlet
Seawater
injectors
Freshwater
injectors
Flow change
cyclone water
separator
WMC
Sea water drain
Fresh water drain
MAN Diesel & Turbo
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14. NOx technology overview
MAN Diesel & Turbo, Low Speed: NOx reduction
technologies
pre-2000
Approved Method
Tier I engine
Tier II tuning
WIF (2009)
SAM (2008)
EGR (2nd gen. 2007)
SCR (2010)
MAN B&W
Tier III
EGR (3rd gen. 2009)
EGR+WIF (2009)
100%
80%
Tier III
60%
40%
20%
Tier II
NOx reduction potential
0%
-20%
WIF: Water/Fuel emulsion SAM: Scavenge Air Moistening EGR: Exhaust Gas Recirculation SCR: Selective Catalystic Reduction
MAN Diesel & Turbo
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15. Tier III NOx Technologies
NOx reduction with SCR
(Selective Catalyst Reduction)
MAN Diesel & Turbo
NOx prevention with EGR
(Exhaust Gas Recirculation)
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16. EGR or SCR
Operation on LNG,
HFO and MGO non
ECA
ECA operation on LNG and
MGO 0,1% sulfur content
Full fuel flexibility incl.
ECA operation on HFO
with high sulfur content
+ EGR
SOX scrubber
or
+
+ SCR
MAN Diesel & Turbo
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17. Tier III EGR
Exhaust Gas Recirculation on MAN B&W engines
1992 Kawasaki, EGR+WIF
2016
2004-12 4T50ME-X EGR
Tier III engine programme
2016
2010
2000
1990
1980
1980
7L67GFC
1991
1L42MC
2010
Alexander Maersk
1992-95 4T50MX EGR
2012 6S80ME-C Tier III
MAN Diesel & Turbo
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18. Basic EGR principle
NO2 formation depends on peak
combustion temperatures and N2/O2
concentrations in the combustion air
Exhaust
gas
loop
Effects by EGR
 CO2 replaces O2 in the
scavenge air.
 CO2 has a higher heat
capacity thus reducing the
compression temperatures.
 Reduced O2 content in the
scavenge air reduces the
peak temperatures.
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19. EGR – principal system layout
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20. EGR – principal system layout
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21. EGR – principal system layout
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22. EGR – principal system layout
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23. EGR – principal system layout
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24. EGR System Layout with T/C cut-out
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25. EGR System Layout with cylinder bypass
MAN Diesel & Turbo
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26. MAN B&W two-stroke diesel EGR engine
Matched for 40% Exh. Gas
Matched for 60% Exh. Gas
Distribution chamber
EGR inlet pipe &
pre-scrubber
Mixing chamber
Dual cooler
EGR outlet pipe
EGR scrubber
EGR blower
MAN Diesel & Turbo
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27. Turbo charging, cut-out design
Description:
• During EGR operation is the
small TC cut out
• The large TC is matched to
60% exhaust gas
• Remaining 40% exhaust gas is
used by the EGR system
MAN Diesel & Turbo
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28. EGR module top
Components
 EGR shutdown valve
 Pre-scrubber gas pipe
 Scrubber water inlet pipes
 Injection nozzles
Description:
• Hot exhaust gas is guided through
the valve to the EGR module
• Scrubber water is injected into the
gas
• Temperature falls to approx
80deg.C due to water evaporation
MAN Diesel & Turbo
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29. EGR control system architecture
ME system
EGR system
User inputs
EGR MOP
ME MOP
EGRCU
EGRI1
EGRI2
MPC’s
MPC 1..n
EGRI3
Engine
MAN Diesel & Turbo
EGRI4
EGRI5
EGR Blower
LEO8
WTS
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30. Gas distribution
Components
• EGR blowers
• EGR gas pipe
• EGR Change over valve
• EGR mixing
Description:
• The cleaned gas is driven by the EGR
blowers
• The gas is guide from the EGR module to
through a change over valve to the normal
air cooler unit bottom
• EGR gas is mixed with normal scavenging
air before the gas mix enters the
scaveneging air receiver.
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31. Water treatment system (WTS)
from Alfa Laval
 Cleans the scrubber water for
reliable scrubber operation.
 Cleans the discharge water to
IMO criteria's.
 Automated control system.
 NaOH dosing.
 Produce pumpable sludge.
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32. EGR key components
On engine
EGR cooler
EGR blower Off engine
Water Treatment System
EGR unit
Drain
Tanks
Control system Scrubber
MAN Diesel & Turbo
EGR sensor
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Valves
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33. Section of
EGR-unit
EGR shut down valve
MET42
Prescrubber
TC cut out valve
EGR-coolers
Outlet for EGR-blower
EGR Scrubber
Reversing Chamber
WMC
EGR Drain system
MAN Diesel & Turbo
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34. EGR control system - HMI
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35. EGR installation example
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36. EGR Service Test on Alexander Maersk
with 3% sulphur HFO
Currently more than 2200 running hours with EGR in
operation is achieved and the crew onboard is
operating the EGR system.
MAN Diesel & Turbo
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37. EGR Service Test on Alexander
Maersk with 3% sulphur HFO

Piston rings

Water mist catcher
MAN Diesel & Turbo

M/E cooler top
EGR housing

Control system
LEO8


Scrubber water cleaning
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38. Service Experience 6S80ME-C9.2
EGR
EGR shoptest Oktober 2012
EGR test run on Sea-trial January 2013
EGR Commissioning trial Marts 2013




Approximately 700 EGR operational hours
Only minor problem experienced
Operated by Crew
No influence on engine components
MAN Diesel & Turbo
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39. Fuel oil consumption – test results
Fuel oil consumption
4
2
0
Mode 1
-4
Mode 3
-6
g/kWh
-2
Mode 4
-8
-10
20
40
60
80
100
Engine load
MAN Diesel & Turbo
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40. Emissions – test results
NOx emission
25,00
g/kWh (ISO)
20,00
15,00
Mode 1
10,00
Mode 3
Mode 4
5,00
0,00
0
20
40
60
80
100
Engine load
MAN Diesel & Turbo
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41. Test results: scrubber and WMC
SO2 and PM before and after MAN B&W EGR2
scrubber @75% load (T12091)
SO2 [PPM]
Particulate matter [mg/Nm3]
120
100
80
60
40
20
0
SO2 in
SO2 out
SO2 PPM
MAN Diesel & Turbo
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PM in
PM out
PM mg/Nm3
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42. EGR 2 – Service Experience
Inspection of EGR gas way through the engine.
MAN Diesel & Turbo
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43. EGR System Layout with T/C cut-out
MAN Diesel & Turbo
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44. MAN B&W two-stroke diesel EGR engine
Matched for 40% Exh. Gas
Matched for 60% Exh. Gas
Distribution chamber
EGR inlet pipe &
pre-scrubber
Mixing chamber
Dual cooler
EGR outlet pipe
EGR scrubber
EGR blower
MAN Diesel & Turbo
LEO8
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45. MAN B&W two-stroke diesel EGR engine
EGR inlet pipe &
pre-scrubber &TC Cut
MAN Diesel & Turbo
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46. Pre-Scrubber + Distribution chamber
Upper pre-scrubber nozzles have
turned themselves
New nozzle-flange-design is
welded and nozzle can’t turn by
themselves.
MAN Diesel & Turbo
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47. Pre-Scrubber + Distribution chamber
Salt deposits on cooler
(the salt will be dissolved by During EGR-running:
water when EGR is running) Scrubber water hits the T/C
Cut Out valve. The water
evaporates and leaves the salt
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48. T/C Cut Out Valve
seem not to be corroded
Hard to see difference salt/rust
MAN Diesel & Turbo
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49. Busan 2013-08-20
No EGR-running for the
previous 2 months
Salt deposit from TC cut out
valve was not removed.
MAN Diesel & Turbo
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Ningbo 2013-08-23
EGR-system been running 2
hours during voyage:
Busan – Shanghai - Ningbo
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50. MAN B&W two-stroke diesel EGR engine
Distribution chamber
Dual cooler
MAN Diesel & Turbo
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51. Dark-coloring in distrubution-chamber
is not corrosion as it can removed
with water
MAN Diesel & Turbo
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52. Salt deposits in ”calm” areas of distributionchamber
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53. Guiding plates installed to prevent EGR gas
and water bypass
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54. MAN B&W two-stroke diesel EGR engine
EGR scrubber
EGR blower
MAN Diesel & Turbo
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55. Scrubber inspection – Looks clean
There is a very thin layer of greasy sooth
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56. Water mist catcher (scrubber-side)
There is a thin layer of non
sticky greasy sooth on the
surface of WMC-lamellas
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57. Water mist catcher
(suction chamber side)
Greasy sooth is not sticking
on the WMC
MAN Diesel & Turbo
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58. EGR-blower suction chamber – Lower part
greasy sooth lumps have accumulated
MAN Diesel & Turbo
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59. EGR-blower suction chamber – Upper part
Thick layer of greasy sooth
the oil-drip-drain seems to work - leading oil directly to the
drain
MAN Diesel & Turbo
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60. EGR-blower suction chamber – Upper part
EGR-blower – not affected by greasy sooth
MAN Diesel & Turbo
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61. Removal oil by blanking of non-return-valves
Change-air is passing through balancing pipe
Non-return-valve blanked in
scav.air receiver
Busan 2013-08-20
MAN Diesel & Turbo
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Inspection of
EGR-blower suction-chamber
(1 week later)
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62. EGR-blower accumulating mix of Water, Oil
and Acid.
May/june 2013
Inspection of EGR blowers
showing accumulated liquid mix
of acidic water/oil in hollow
space of impeller-housing
According to Siemens, not a
problem however they
recommended a permanent
drain.
MAN Diesel & Turbo
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Drains installed in
Busan August 2013
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63. MAN B&W two-stroke diesel EGR engine
Mixing chamber
EGR outlet pipe
MAN Diesel & Turbo
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64. EGR-pipe
(from EGR-blower to EGR-mixing-chamber )
MAN Diesel & Turbo
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65. EGR-mixing-chamber
Greasy sooth have been
carried by the EGR-gas
MAN Diesel & Turbo
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66. EGR-mixing-chamber
Bigger greasy sooth lumps have
fallen down or got stuck in the
WMC.
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67. Continuously development O2-sensor-setup
Present O2-sensor-setup at Maersk
Cardiff
Only manual calibration and only
surveillance of sensors
MAN Diesel & Turbo
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New setup – currently testing at our
test-engine.
With automatic calibration and
surveillance of
sensors/pressures/flow.
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68. EGR2 –Service Experience
Drain Pipes
• Drain pipes from ME WMC.
• Permanent solution; In EGR operation to lead drained liquid back to WTS
MAN Diesel & Turbo
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69. EGR concept and maturing
1. Standard Tier III EGR
March
2013
Jan
2016
2. Maturing level 1 - reliability
3. Maturing level 2 - cost
4. New concept development
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70. SCR Reference List
for MAN B&W 2-stroke Engines
8K45GF
ship
Post turbine
6S50MC
ship
NOx reduction 93-95%
1989
6S50MC
ship
NOx reduction 93-95%
1990
6S50MC
ship
NOx reduction 93-95%
1991
6S50MC
ship
NOx reduction 93-95%
1992
12K80MC-GI-S
Chiba, Japan
NOx reduction up to 98%
1993
4L35MC-S
Mannheim, Germany
NOx reduction >93%
1995
4x7K60MC-S
Nam Cheju, Korea
NOx reduction >93%
1998
6S35MC
ship
NOx reduction >93%
2002
2x9K80MC-S
Macao
NOx reduction >93%
2002
2x12K80MC-S
Macao
NOx reduction >93%
2003
2x12K90MC-S
Macao
NOx reduction >93%
2003
12K80MC-S
Buk Cheju I, Korea
NOx reduction >88~95%
2005
12K80MC-S
Buk Cheju II, Korea
NOx reduction >88~95%
2008
7L35MC-S (Bio) Brake, Germany
NOx reduction>98%
2008
6S46MC-C
Tier III
2011
MAN Diesel & Turbo
Ship
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Start 80’ties
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71. SCR
SCR Challenges on 2-stroke engines
•
•
•
•
•
MAN Diesel & Turbo
Sulfur content in fuel oil
(NH4)2SO4  ABS
Operating Temperatures
Ammonium slip
Transient in engine load (Temperatures)
Before or after TC installation
• Before T/C, compact installation on engine.
• After T/C, larger installation and lower temperatures.
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72. SCR Pre- Turbo Charger installation
Vaporiser/mixer
V1
V3
V2
SCR
Reactor
V4
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Fyns Maritime Klynge
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73. Tier III SCR System
Pre-turbine SCR
Tier III operation
– The exhaust gas is
directed to the SCR
reactor
MAN Diesel & Turbo
LEO8
Fyns Maritime Klynge
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74. SCR and Two-Stroke Diesel Engines
Challenge
SCR temperature requirement for operation on HFO is min. 330°C
MAN Diesel & Turbo
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Fyns Maritime Klynge
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75. SCR Pre-TC valves system
Tier II SCR system is cut off
• V2 and V3 is closed
• V1 is open
Reducing
agent
Vaporizer/mixer
V2
SCR
Reactor
Tier III SCR system is in operation
• V2 and V3 is open
• V1 is closed
V4 (SCR bypass) used to increase
temperatures at low engine load
Exhaust gas receiver
V1
V3
V4
Scavenge air receiver
MAN Diesel & Turbo
LEO8
Fyns Maritime Klynge
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76. SCR and Two-Stroke Diesel Engines
Result
SCR temperature requirement for operation on HFO is min. 330°C
MAN Diesel & Turbo
LEO8
Fyns Maritime Klynge
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77. Tier III Achievement Further Work
Gathering service experience
MDT and Hitachi Zosen Corporation
are looking forward to proving the
designs in service
Santa Vista information
 IMO number: 9527946
 Vessel Name: SANTA VISTA
 Name of the shipyard: NAIKAI ZOSEN
 Vessel Owner: BOT Lease Co., Ltd.
 Hull number: 744
 Operator: NISSHO Shipping Co., Ltd.
 Vessel type: 38,000 DWT, general
cargo carrier
MAN Diesel & Turbo
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Fyns Maritime Klynge
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78. SCR HMI
MAN Diesel & Turbo
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Fyns Maritime Klynge
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79. Do you have any more questions?
Jesper Gram
Jesper.Gram@man.eu
LEO8@mandieselturbo.com
MAN Diesel & Turbo
Teglholmsgade 41,
2450 Copenhagen SV
Denmark
Phone (main) +45 33 85 11 00
Phone direct +45 33 85 29 36
MAN Diesel & Turbo
LEO8
Fyns Maritime Klynge
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80. Disclaimer
All data provided in this document is non-binding.
This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual projects, the relevant data may be subject
to changes and will be assessed and determined individually
for each project. This will depend on the particular
characteristics of each individual project, especially specific
site and operational conditions.
MAN Diesel & Turbo
LEO8
Fyns Maritime Klynge
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