New Technologies for Emission Control in Marine Diesel Engines

297 Pages·2019·14.576 MB·English

by  Kuwahara, Takuya, Okubo, Masaaki

NEW TECHNOLOGIES
FOR EMISSION
CONTROL IN MARINE
DIESEL ENGINES
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NEW TECHNOLOGIES
FOR EMISSION
CONTROL IN MARINE
DIESEL ENGINES
MASAAKI OKUBO
TAKUYA KUWAHARA
Butterworth-HeinemannisanimprintofElsevier
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Contents
Preface vii
1. Introduction 1
1.1 Classificationofships 1
1.2 Marinedieselenginesinsideships 9
1.3 Mechanismofdieselengines 13
1.4 Targets ofemissioncontrol 23
References 24
2. Emission regulations 25
2.1 EstablishmentofMARPOL73/78Convention 25
2.2 NO regulations 26
x
2.3 SO regulations 34
x
2.4 Particulate matterregulations 37
2.5 Fuelregulations 42
References 50
3. Principle and design of emission control systems 53
3.1 Airpollutantsgeneratedinexhaust gas 54
3.2 NO control 68
x
3.3 SO control 86
x
3.4 Particulate mattercontrol 95
3.5 PlasmatreatmentsforNO andparticulate matter 118
x
References 142
4. Operation examples of emission control systems 145
4.1 Selectivecatalytic reduction 146
4.2 SO scrubber 153
x
4.3 Electrostatic precipitator 159
4.4 Computational fluiddynamicsfortwo-phase flowsinelectrostatic
precipitators 163
4.5 Laboratory-scale plasma particulatematterdecomposition 178
4.6 Pilot-scale plasmaparticulate matterdecomposition 184
4.7 PlasmaNO reduction 192
x
4.8 Exhaustgasrecirculation method 202
References 208
v
vi Contents
5. Prospects for marine diesel engine emission control 211
5.1 AdvancedNO controltechnologies 212
x
5.2 AdvancedSO controltechnologies 228
x
5.3 Volatileorganiccompound emissioncontrols 235
5.4 PM andhealtheffects 239
2.5
5.5 ReductionofCO emissionsfrommarineengines 247
2
5.6 Past,current,andfuturemarkets foraftertreatments 256
5.7 Operation andmaintenance ofaftertreatmentsystems 259
References 264
Appendix 267
Index 275
Preface
Recently, emission controls for combustion engines have become an
important topic in environmental technology. Emission controls can be
classifiedintotwotypes:combustionimprovementforlow-emissionengines
and aftertreatment/exhaust gas cleaning. The main objective of this book is
to present readers with an easy-to-understand resource for the foundation
and application of technologies for marine diesel engine emission control.
This book describes different types of emission control technologies for
marine diesel engines and attempts to be the first book of its type to treat
these topics. Further, this book provides a bridge from fundamentals to
practical industry applications in environmental engineering. Diesel engines
have the advantages of low carbon dioxide (CO ) emission, compact size,
2
and higher fuel efficiency relative to output power. However, their emis-
sions contain harmful particulate matter (PM) and nitrogen oxide (NO ),
x
and control technologies for them are required. Combustion improvements
for low-emission engines are important, such as fuel injection systems and
dual-fuelsystems,and,therefore,shouldbeinvestigatedprimarilyasemission
control technologies. On the other hand, aftertreatment technologies for
emissions have been extensively developed in recent years and are the most
effective means of emission control. Because regulations on automobile
emission are already in place in developed countries, marine diesel engines
shouldbethenexttarget.TheNO concentrationinmarinedieselemissions
x
isrelativelyhigh(500e1000ppm).Furthermore,themarinedieselemissions
contain sulfur oxides (SO ) and PM. This is because the engines are
x
operated using marine diesel oil or marine fuel oil fuels, which contain a
significant amount of sulfur with the concentration of several percent at
most. It has been suggested that emissions from marine diesel engines of
ocean-faring ships could contribute to climate change and increase the
risk/incidence of respiratory diseases; therefore, stringent regulations and
its keeping are needed.
This book mainly focuses on emission control for marine diesel engines,
butemissioncontrolsforautomobileandoff-roadenginesarealsodescribed.
Becausemarinedieselenginesareusuallyfueledbyheavyoilincludingsulfur
andnitrogen,emissioncontrolismoredifficulttoincorporatecomparedwith
automobile diesel engines. This is because the latter utilizes gas oil, which
vii
viii Preface
contains much less sulfur and nitrogen. However, because the rotational
speedsofmarine dieselengines are usually steady, emissions are induced ata
steady rate and thus are easier to control. Conversely, automobile engine
emissions fluctuate because the rotational speed of the engine varies more
frequently; thus, its emissions are more difficult to control. The complete
removalofthesepollutantsfromenginesinourlaboratorywasveryexciting
experience for us, and we hope that some of our fascinations with this
technologyisexpressedinthebook.
Ourinitialstudiesweremotivatedbythedesiretocleanstationaryfossil
fuel (coal-, oil-, and gas-fired) power generation plants emissions and clean
exhaust gases, including dioxins, emitted by garbage incinerators. The
cleaning methods utilized new technologies that incorporated nonthermal
plasmas. Recently, almost all power generation plants in Japan have been
equipped with an environmental system composed of selective catalytic
reduction, electrostatic precipitator, and soda-lime gypsum methods, and
simultaneous removal of NO ePMeSO with high efficiency has been
x x
achieved. As a result, Japanese skies have been kept very clear. However,
earlyinthe2000s,emissioncontrolforautomobiledieselenginesbecamea
problem in Japan and in other western countries. We began JST
(Japan Science and Technology Agency) project to control diesel engine
emissions. The main cleaning technology used in the project was also
nonthermal plasma. Similar to the outcome of other diesel engine projects,
our project developed a new aftertreatment system for super-clean auto-
mobile diesel engines. As a result of another our combustion emission
cleaning project, a super-clean industrial boiler was successfully developed
with a NO emission level of less than 10ppm. Recently, marine diesel
x
engines with NO , SO , and PM controls have attracted attention, and
x x
efforts have been devoted to further develop this research field in marine
engineering. We believe that these research developments should be
documented,andthuswehavewrittenthisbooktoconveytechnologiesto
future generations.
These projects were accomplished mainly at Osaka Prefecture
University in Sakai city, Osaka Prefecture, Japan, which has been the main
researchinstitutionoftheauthors.Sakaicityhasprosperedoceantradesince
long ago. In the 16th century, it was called “Oriental Venice” known as
“Saccai” to Europeans and was imaged as a prosperous international trade
port. As an image of the prosperous Sakai of those days, there is a drawing
picture published in a book written by Dutch missionary and scholar,
Arnoldus Montanus, in the 17th century as shown in Fig. A.1 in A.2
Preface ix
of Appendix. There are various international ships going at Sakai port. At
thepresenttime,SakaicityhasdevelopedasanindustrialcityinJapanwith
a large factory zone in the coastal area. We are delighted to be able to
publish this technical book on the marine environmental technology from
Osaka Prefecture University located in the traditional Japanese city.
The recent developments in aftertreatment technologies and their
fundamental aspects are included in this book. Selected applications of
emission control technologies are also described. Some of them have been
completedinthecommercialstage,whileothersarestillintheearlystageof
development. The technical details and test results are described based on
the fundamental knowledge of environmental protection engineering. One
of the authors, Masaaki Okubo, has experience teaching master’s courses of
graduate school at Osaka Prefecture University. The title of one of the
classes is Environmental Protection Engineering for the Department of
Mechanical Engineering and the Department of Aerospace and Marine
Engineering.Thisbookisintendedtobeatextbookfortheclass.Although
the booktreatsmainlyemission controlinmarine dieselengines,itincludes
descriptions of the overall technology for air cleaning. Discussions with
Dr. Tomoyuki Kuroki at Osaka Prefecture University have been
enthusiasticandproductive,andweareappreciativeofhisdiscussionwithus
on the various topics treated in this book.
Emission control technology is an interdisciplinary topic that is physical
and chemical in nature, with applications in mechanical, chemical,
environmental,andmarineengineering.Becausepractitionersinthesefields
have diverse backgrounds, an effort has been made to devise a technology
that is sufficiently self-contained to beaccessibleto engineers, scientists, and
students from many fields.
Chapter1providesanintroductiontoclassifythedifferenttypesofships,
fundamentals of marine diesel engines, their mechanism, and emissions.
Further,targetsofemissioncontrolinthisbookisdescribed.Chapter2treats
recentmarineandautomobileemissionregulationsforNO ,SO ,PM,and
x x
fuels. Chapter 3 treats the principle and design of emission control systems
for marine and automotive applications. The fundamentals of control
method for air pollutants generated in exhaust gas such as NO , SO , and
x x
PM are presented. The fundamentals of environmental protection
engineeringarealsodescribedforenhancedunderstandingofthatfield.The
conceptofelectrostatics,plasmadischarge,andelectrostaticprecipitationare
rarely included in any contemporary curriculum. Accordingly, their
importantfundamentalaspectsareincludedinthechapter.Furthermore,the