Green Ship Magazine

Green Ship Magazine
Together we make a difference

Including summary of ‘Low Emission Concept Ships’ study
Learn more about how leading and innovative Danish maritime companies work
together on reducing air emissions from shipping and shipbuilding.

Danish Minister for economic and business affairs......3

The shipping industry needs ....................................4

Exhaust gas scrubbers .............................................7

Performance manitoring and trim optimization...........8

/RZHU VKLS VSHHGV ZLWKLQ FHUWL¿FDWLRQV......................9

$ ÀRDWLQJ FRROLQJ ODE .............................................11

Being in tune reduces fuel consumption ..................13

ABB turbocharging reduces fuel consumption ..........14

Emission reduction using exhaust gas recirculation .. 15

From complexity to opportunity ..............................16

Low emission ship concept studies .................... 17-24

Without a green consciousness ..............................25

System integration and waste heat utilisation ..........27

Machinery for high-speed LNG-ferries .....................29

Optimization of CO2 HPLVVLRQ DQG IXHO HI¿FLHQF ...... 30

NOX reduction on marine engines ...........................31

A collaboration to help international shipping ..........32

Optimization of pump ............................................33 Printing:
Rosendahls,
Exhaust gas waste heat recovery............................35 Esbjerg, Denmark

(I¿FHQW URXWH SODQQLQJ...........................................36 Circulation:
10.000
Performance monitoring of new silicone antifouling.. 37
Layout:
Adding water to the fuel ........................................38 Seapress ApS
DK-8270 Hoejbjerg
Organisations ........................................................39 Jeanette Løgstrup

2

Green Shipping
is the future
In recent years, sustainability in a climate In Denmark we have learned that
and an environmental perspective has successful innovation can only be achieved
become an issue of highest priority. This through interplay of cooperation and
is an agenda that cannot and should not rivalry. Therefore, it is necessary to bring
be ignored. Therefore, I am pleased to together companies, research, innovation
see how the Danish Maritime Cluster has and education. That is what the Green
combined its forces to act constructively Ship of the Future project is about.
and innovatively to make green shipping
a reality. The Green Ship of the Future cooperation
has embarked on the right course
7KH ¿QDQFLDO FULVLV KDV UHYHDOHG D with a strong focus on near-to-market
vulnerable global society. Fortunately, the innovations addressing issues in relation
latest developments have shown signs of to climate and the environment. As an
recovery thanks to deliberate and well- open cooperation between companies and
coordinated global political actions which knowledge institutions, an active platform
KDYH FUHDWHG QHZ FRQ¿GHQFH DPRQJ for innovation of new technologies and
companies and consumers. This political systems has been created.
commitment can be seen as a recognition
that global production and trade create The achievements of the Green Ship of
wealth for all of us – with shipping and the Future cooperation are a showcase of
associated maritime industries as the a vibrant Danish Maritime Cluster offering
primary enablers. HQHUJ HI¿FLHQW DQG HQYLURQPHQWDOO
friendly products and services.
In order to keep focus on the important
agenda of sustainable and green shipping With these words I welcome you to the
HYHQ LQ GLI¿FXOW WLPHV ZH PXVW Green Ship of the Future.
WXUQ WRZDUGV LQQRYDWLRQ DQG HI¿FLHQW
regulation.

Within a foreseeable future, shipping
will still be dependent on fossil fuels.
We must work hard to develop energy
HI¿FLHQW DQG HQYLURQPHQWDOO IULHQGO
technologies encompassing shipboard
energy production and propulsion of the
ship as well as ship operation. What we
gain on propulsion and operation will be
valid in a non-fossil future.

Another important aspect is the work
done by the International Maritime
Organization, which is the key player in
setting regulations applicable for all ships
LUUHVSHFWLYH RI ÀDJ , DSSUHFLDWH WKH ZRUN
Fotograf: Helle Moos

done so far, recognizing that we still have
an extensive workload in front of us. The
regulations to be set for safe, secure and
environmentally sustainable shipping
must be goal-based instead of prescribing
VSHFL¿F VROXWLRQV 6XFK UHJXODWLRQ FUHDWHV
DPSOH URRP IRU LQQRYDWLRQ RI QHZ HI¿FLHQW Lene Espersen
technologies and operational standards. Danish Minister for Economic and Business Affairs

3

The shipping industry needs
Green Ship of the future
Almost 90 % of the world trade is carried by ship and for the Ships are the most environmentally friendly form of
vast majority of this trade there is little or no alternative to transportation. Still, with 90 % of the world trade being
transport by ship. It is estimated that 2.7 % of the global CO2 transported by ship, it is inevitable that shipping contributes
emissions come from international shipping. to unwanted emissions from transportation. The Danish
maritime cluster is very aware of this and has a strong focus
The environmental policies of the Danish shipping companies on making waterborne trade even more environmentally
should be seen as a long term strategy to reduce energy friendly than it already is.
FRQVXPSWLRQ DQG LPSURYH HQHUJ HI¿FLHQF 7KH 'DQLVK
PHUFKDQW ÀHHW LV DPRQJ WKH PRVW HQHUJ HI¿FLHQW LQ WKH ZRUOG Danish maritime manufacturers have been developing
due to its young age and the focus Danish shipping companies WKHLU SURGXFWV LQ HQYLURQPHQWDOO EHQH¿FLDO GLUHFWLRQV
have for many years had on investments in new technology. for many years. The main thrust is towards reducing the
energy requirement of ships and the environmental impact
The Danish Shipowners’ Association would like to see of the production process and of the vessels themselves.
international regulation adopted by the International Maritime We continue to develop still more environmentally sound
Organization, IMO. Only IMO can guarantee international solutions, and recent efforts have been focused on
UXOHV WKDW DSSO WR DOO VKLSV UHJDUGOHVV RI ÀDJ DQG WKLV LV RI mitigating the climate effects
paramount importance to avoid distortion of competition in a
global industry. Members of Danish Maritime develop equipment of many
types from main engines to lifesaving equipment or
The Danish Shipowners’ Association believes that the merchant scrubber systems. Most are major producers and front
ÀHHW ZLOO EH DEOH WR LQFUHDVH LWV HI¿FLHQF E DW OHDVW E line developers. Their products are universally available
2020. Green Ship of the Future is a very important instrument DQG FRPSHWLWLYH DOO RYHU WKH ZRUOG ,W ZRXOG EH GLI¿FXOW
because only by close cooperation within the industry can we WR ¿QG YHVVHOV WKDW GR QRW FDUU 'DQLVK HTXLSPHQW RU
achieve this target. Green Ship of the Future is a vital platform engines. This implies that improving Danish products will
for the entire maritime industry when testing and developing reduce emission from vessel all over the world. This brings
new products, and the entire industry sends a strong signal on a very important responsibility to ensure that modern
when working closely together in research and development – environmentally friendly equipment is available.
DQG DW WKH HQG RI WKH GD WKH HQWLUH LQGXVWU ZLOO EHQH¿W IURP
Green Ship of the Future. The Danish maritime cluster wishes to play an important
role in designing and developing environmentally
Danish shipping companies are doing their part and expect responsible products that minimize emissions. With Green
especially transport buyers to also focus on climate friendly Ship of the Future the Blue Denmark is making an extra
transport solutions. effort to protect the climate and environment.

Jan Fritz Hansen, Executive Vice President, Michael Prehn
The Danish Shipowners’ Association Deputy director

4

Green Ship of the future

Reducing emissions is not achieved simply by reducing the total transportation
by ship. Growth in consumption and economy and a growing need for transport
services with a greater share of transportation by sea brings about a need for
more shipping.

In recognition of the ecological responsibility nested in the maritime industry, a
group of private Danish maritime companies – including market leaders such as
Aalborg Industries, A.P. Moller-Maersk, MAN Diesel and Odense Steel Shipyard
– has initiated Green Ship of the Future with the primary objective of developing
and demonstrating green technologies within shipping and shipbuilding.

Green Ship of the Future is a unique cooperation in which companies across the
Danish maritime industry join forces in order to develop strategies to reduce
CO2 by 30 %, SOX by 90 %, NOX by 90 % and particulate emissions from both
existing ships and newbuildings. Participation is open for all Danish companies
and organisations that meet the condition of being able to demonstrate a
technology for reduction of air emissions within one of the four focus areas:
machinery, propulsion, operation and logistics.

Combining forces
Many elements are coming together in Green Ship of the Future:
research, development, demonstration, innovation, education, training and
GLVVHPLQDWLRQ RI NQRZOHGJH 0DQ ¿HOGV RI NQRZOHGJH DUH LQYROYHG VXFK DV
systems for recycling heat energy, optimization of the hull, propellers and
rudders, optimization of the draft and speed for a given route and arrival time
and monitoring the fouling of hulls and propellers. Engine technology is an
HVVHQWLDO IDFWRU IRU DFKLHYLQJ WKH SODQQHG EHQH¿WV

This unique initiative is met with great interest all over the world.
In July 2009, Green Ship of the Future received the International Environmental
Award from the Sustainable Shipping organisation for
being the most environmentally friendly shipping
initiative.

Since its foundation, Green Ship of
the Future has experienced great
success. From the starting point
with four project partners, the
group of companies has expanded
dramatically and today consists of
23 dedicated project partners. The
typical partner has its main business
within the maritime industry, but
also universities, interest groups and
national authorities support Green
Ship of the Future – underlining the
impression that together we really do
make a difference.

5

When it comes to the sea the sky’s the limit

www.clipper-group.com

Green Solutions
Aalborg Industries is the market
leading manufacturer of highly ef-
ﬁcient and environmentally friendly
equipment for the maritime market.
Our green solutions encompass:

„ M.E. Exhaust gas scrubbers
„ Ballast water treatment
„ Waste Heat Recovery
„ Superheater for aux. boilers
„ Cooling System for LNG
„ MGO burner modiﬁcations
greentech@aalborg-industries.com
„ Economizer after aux. engines
www.aalborg-industries.com

WE WOULD NEVER
SOIL NATURE
L T R
EVEN THOUGH NATURE
H U H
OFTEN SOILS US.
E IS

6

Exhaust gas
scrubbers
The scrubbing process in the Aalborg
Industries system consists of three stag-
HV $W WKH ¿UVW VWDJH WKH H[KDXVW JDV
o
The future international regulations is cooled from approximately 350 C to
o
regarding sulphur emissions from 160-180 C in a conventional exhaust gas
ships imply that low sulphur fuel economizer that uses the extra heat in
should be used in the future; other parts of the system instead of just
however, exhaust gas scrubbers wasting it. At the second stage, the ex-
are allowed as an alternative to haust gas is treated with a special ejector.
actually lowering the fuel sulphur Here the exhaust gas is further cooled by Olav Knudsen from Aalborg Industries
content. injection of water removing the majority explains, ‘During the winter of 2008/09,
of the soot particles. Finally, the exhaust a comprehensive range of tests was car-
Scrubbers can be used for washing the gas is led through an absorption duct ried out together with MAN Diesel in their
exhaust gas from the main engine and where the exhaust gas is sprayed with test facility in Holeby, Denmark. The test
can, in principle, be compared to a large water and thus cleaned of the remain- proved that we are able to remove almost
shower cabinet placed in the funnel of ing sulphur dioxide. To prevent visible 100% of the sulphur from the exhaust gas
the ship. With Aalborg Industries’ newly condensation and corrosion, the exhaust and up to 80% of the particles. In June
developed scrubbing system, it is pos- gas is subsequently reheated before be- RXU ¿UVW VFUXEEHU LQVWDOODWLRQ ZDV
sible to reduce the sulphur emissions to ing discharged through the funnel of the supplied and installed on a DFDS Ro-Ro
a level as low as if low sulphur fuel oil ship. cargo vessel and in late 2009, we expect
was used. But because low sulphur fuel to complete the installation and make the
RLO KDV D VLJQL¿FDQWO KLJKHU FRVW SULFH LW Extensive testing commissioning on board the ship.’
PDNHV JRRG ¿QDQFLDO VHQVH WR XVH VFUXE- The scrubbing system has undergone
bers to clean off the exhaust gas and extensive testing with good results.
thereby continue using heavy fuel oil.

The method
7KH PDMRU HQYLURQPHQWDO EHQH¿W IURP
the scrubbing system developed by Aal-
borg Industries is that both seawater and
freshwater mixed with caustic soda can
be used for the scrubbing. This makes
the scrubbing process more environmen-
tally safe than using chemicals to clean
the exhaust gas of emissions.

Project facts

Category: Machinery
Emission reductions:
CO2 3 % (compared to converting
+)2 WR 0*2 LQ UH¿QHULHV

SOX 98 %
PM 80 %

Partners:
Aalborg Industries A/S
MAN Diesel
DFDS

7

Performance monitoring and
trim optimization
The ship resistance and the ship’s After building a scale model of the
trim are closely connected to CLIPPER tanker, it was tested in FORCE Project facts
each other. When the ship has the Technology’s towing tank. To obtain data
right trim, the water resistance is for the trim matrix, a series of tests was
at a minimum, and so is the fuel performed in the normal operation range Category: Operation
consumption. A project by CLIPPER of the vessel. During the tests the vessel
GROUP and FORCE Technology will speed, propulsive power, sinkage and Emission reductions:
uncover the potential fuel reduction trim were measured. More than 100 test
gained by sailing at optimum trim. points were evaluated in the operation CO2 3%
range. NOX 3%
The purpose of the project is to SOX 3%
demonstrate the fuel reduction when the Full-scale validation
ship is trimmed correctly and to validate In order to validate the test results, the Partners:
SeaTrim as a tool to achieve this fuel SeaTrim application has been installed on CLIPPER GROUP
reduction. The ship used in this project six of CLIPPER’s chemical tankers. In the
is an L-Class chemical tanker owned and coming period, SeaTrim will be used to FORCE Technology
operated by CLIPPER GROUP. optimize the tankers’ trim and measure
their fuel consumption.
How to trim correctly Before SeaTrim was implemented on
SeaTrim is one of the advanced tools board the six CLIPPER vessels, a desktop
in the SeaSuite portfolio from FORCE study of the saving potential was made.
Technology. SeaTrim is based on a trim The study looked at the history of one of
matrix where the optimum trim can be the six vessels regarding the trim and the
read as a function of displacement and ship’s speed. The desktop study showed
ship speed. The SeaTrim application that there was a potential for fuel oil
gives the ship operator a graphical saving in approximately 80% of the sea
SUHVHQWDWLRQ RI WKH LQÀXHQFH RQ WKH IXHO voyages.
consumption as a result of a change to
trim and draught. Kaj Pilemand from CLIPPER Group In order to uncover the full potential
says, ‘Even though we have very skilled of SeaTrim, FORCE Technology´s
Starting in model scale crew on board our vessels, there is performance validation tool SeaTrend
‘The most accurate and controlled way to always room for improvement’, and he is installed on board the six ships. This
obtain information about the propulsive continues, ‘With fuel oil consumption program will monitor and validate the
power requirement for a ship is to build of 2.800 tons per year/ship, even small performance of SeaTrim. The results of
a scale model and test the model in our savings percentwise are welcome – This the project will be known in approximately
towing tank,’ says Rasmus Carstens, is healthy both for the environment and one year when the full scale data have
project manager on the project at FORCE for business’. been analysed.
Technology.

8

Lower ship speeds
ZLWKLQ FHUWL¿FDWLRQV
Ships are designed for certain are reduced. the main engine power will decrease
speeds. For a large range of ships, The second solution is cutting out the approximately from 77% to 56% load.
the required ship speed is declining turbocharger which is possible on ships The lower ship speed will cut emissions
due to increased focus on fuel oil with multiple turbocharger engines. by 25% per sailed nautical mile. The
consumption and CO2 emissions. This solution has a wider scope as it is additional decrease of CO2 emissions
Also, the present slow-down in possible to gain larger reductions of fuel due to the optimized engine operation
the world economy has further consumption than by using low-load with turbocharger cut out will reduce CO2
increased the demand for lowering mode on electrically controlled engines. emissions by another 3%.
ship speeds. Furthermore, turbocharger cut out can
be used on both electronically controlled
A large part of the main propulsion engines and mechanical engines. This Project facts
engines installed on large ocean-going increases the possible reduction of
ships are low-speed two-stroke diesel exhaust gas emissions as most ships Category: Machinery
engines. These engines are designed for today are propelled by mechanical
a certain power output corresponding engines.
to the ship’s speed. As the propulsion Emission reductions:
power demand decreases, changes to The method of turbocharger cut out works CO2
engine components and adjustments are by turning off one of the turbochargers NOX
EHQH¿FLDO IRU WKH LPSURYHPHQW RI IXHO RLO and closing one of the throttles. This SOX
consumption, lowering of CO2 emissions FDXVHV WKH HQJLQH WR UXQ PRUH HI¿FLHQWO
and for improvement of the overall and in combination with reduction of the Partners:
performance of the engine. This will lead ship’s speed, fuel oil consumption and A.P. Moller-Maersk
to optimized low-load operation of the CO2 emissions are reduced. MAN Diesel
engine. However, the changes affect the Turbocharger cut out is already
HQYLURQPHQWDO FHUWL¿FDWLRQ RI WKH HQJLQH implemented within the current
especially with regards to NOX emissions. FHUWL¿FDWLRQ RQ WKH $3 0ROOHU 0DHUVN
8.000 TEU container ship Maersk Salalah
When a ship engine is manufactured, it with a MAN BW 12K98ME main engine.
XQGHUJRHV D FHUWL¿FDWLRQ WHVW LQ RUGHU WR Tests on the ship shows that by lowering
assure that emissions are within the IMO the ship speed from 24 knots to 22 knots,
regulation limits. When making changes
on an original engine, it is necessary to
UHQHZ WKH FHUWL¿FDWLRQV ZKLFK LV D WLPH
consuming and costly affair.

7KHUHIRUH WKLV SURMHFW WULHV WR ¿QG
solutions for low-load optimization of the
H[LVWLQJ YHVVHO ÀHHW ZLWKLQ WKH FXUUHQW
FHUWL¿FDWLRQV

Low-load sailing and turbocharger
cut out
Many different possibilities have been
investigated, and the two solutions with
the greatest potential have been further
GHYHORSHG 7KH ¿UVW VROXWLRQ LV VDLOLQJ WKH
ship at low-load mode which is possible
for electronically controlled engines.
Ship engines are constructed to have
optimal fuel consumption at a certain
speed. By sailing at low-load mode
with electronically controlled engines,
this optimum is reached at far lower
speeds than normally. By doing so, the
consumption of fuel and air emissions

9

Mols-Linien – The Floating Kattegatbridge
introducing The High-Speed Ferry of the Future

2

2

Mols-Linien A/S supports development of new and better 0HPEHU
/
:-
-6 ;0
1

8
technology in cooperation with Green Ship of the Future. RI 7
.
0
- .==
:-

www.mols-linien.dk · Phone +45 89 52 52 00 Your short cut through Denmark

ABB Turbocharging.
Setting a new standard.

ABB Turbocharging introduces the all-new A100 turbocharger generation as a significant step in the devel-
opment of single-stage, high-efficiency, high-pressure turbocharging. Three A100 series set a new standard
with highest compressor pressure ratios for the high-speed and medium-speed diesel and gas engine
segments as well as highest efficiency at high pressure ratios for low-speed diesel engines. For further infor-
mation please contact ABB Turbo Systems Ltd, Baden /Switzerland. www.abb.com/turbocharging

DANSK TEKNOLOGI Produktionsaktieselskab
24 Østre Teglværksvej, DK3450 Allerød
Phone: +45 48135000 ˜ www.dansk-teknologi.dk

WORLD CLASS INNOVATION
x Product development x 800+ successful projects
x Cleantech innovation x From idea to detailed implementation
x Manufacturing systems x Outstanding track record
x Development and x Clients are top 2 world leaders e.g.
installation of SCR-systems Airbus, A.P. Møller-Mærsk, Grundfos

10

$ ÀRDWLQJ
cooling lab
Large amounts of electric energy On the 7,000 TEU container ship Gudrun Long-term gains
are consumed when cooling water is Maersk, this should generate 980,000 The long-term goal of the project is to
pumped to cool components in the kwh/year energy savings which equal provide a decision package that scopes
engine room. A.P. Moller - Maersk 235 tons fuel oil and 731 tons CO2 a out different possible improvements and
targets the potential savings with a year. The energy savings are estimated in their impact on ship economy as well as
project set to scope out best prac- a master’s thesis from Aalborg University, the environment. The calculated savings
WLFHV IRU UHWUR¿W DQG EXLOGLQJ RI QHZ ZKLFK KDV EHHQ FRQ¿UPHG E FRROLQJ VV- are based on the simple constant pres-
ships. Therefore, a 3 year industrial tem simulations based on data collected sure system which will be used in the
Ph.D. at Aalborg University will turn by the A.P. Moller – Maersk Ship Perfor- beginning as it is a safe and predictable
*XGUXQ 0 UVN LQWR D ÀRDWLQJ FRRO- mance System, MSPS. In addition to the option. The project partners expect to in-
ing lab in pursuit of the perfect cool- HQYLURQPHQWDO EHQH¿WV WKH SDEDFN WLPH crease savings with more advanced and
ing solution for the 21st century. for the shipowner will be less than 2 years. VHOIWXQLQJ FRQWURO DOJRULWKPV 7KH ÀHHW
roll-out decision package is expected to
The cooling system is a key component in Keeping cool and stable evolve over time as more knowledge and
the ship’s safety, and the main challenge In order to obtain these savings, vari- experience is gathered.
is to keep the low temperature cooling DEOH IUHTXHQF GULYHV 9)'

YDOYHV DQG
system stable. Today, a cooling system is smart control algorithms need to be
driven by a constant speed pump which implemented. VFD’s and valves are al-
ensures a stable temperature when used ready off-the-shelf items but safe and
WRJHWKHU ZLWK PL[LQJ FLUFXLWV DQG ¿[HG energy-optimal control algorithms for
ÀRZ UHVWULFWLRQV 8QIRUWXQDWHO E XV- ships have not been developed yet.
ing a constant speed pump, the cooling The cooling system is a key component
system is running at an overall higher in the ship’s safety, and the main chal-
capacity than needed. By changing from lenge is to keep the low temperature
constant speed pumps to variable speed cooling system stable. Therefore, an in-
pumps, the energy consumption will be dustrial Ph.D. at Aalborg University will
reduced, and at the same time the need focus on combining fault tolerance and
for mixing circuits will be removed. Fur- robust control with self optimization.
thermore, the use of valves on subsys-
WHPV ZLOO UHSODFH WKH QHHG IRU ¿[HG ÀRZ
restrictions.

Project facts
200
180
Category: Machinery
160
Power savings [kw]

140
15C Seawater CO2
120
20C Seawater NOX
100 24C Seawater SOX
28C Seawater
80 Partners:
32C Seawater
60 A.P. Moller-Maersk
40 Odense Steel Shipyard
20
-
0 20 40 60 80 100
Main engine power [%MCR]

11

APV Global Marine
Water Desalination Unit Plate Heat Exchanger

Up to 60 T/24 Hours Multitude of plate designs
Single stage plate type Patented corner lock
Stainless steel vessel Patented easy-clip gaskets
Steam injection In-line filter
UV re-hardening filters

Platinvej 8
6000 Kolding - Denmark
Phone: +45 70 278 444
E-mail: marine.kolding@apv.com
www.apv.com

6 9 ( 1 ' % 2 5 * , 1 7 ( 5 1 $ 7 , 2 1 $ / 0 $ 5 , 7 , 0 ( $ $ ' ( 0 - a mil ahead...
mile

SIMAC offers maritime
education programmes
that meet the standards
of Quality Shipping
We provide our students with a solid foundation
for becoming future leaders in the maritime world
through a modern, value based, quality assured
and internationally recognized education at B.Sc.
level.
6,0$ ‡ *UDDHVYHM
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'. 6YHQGERUJ
3KRQH ‡ PDLO#VLPDFGN
3KRQH

Read more on simac.dk – or call us for further information

DTU creates climate
change solutions
We need climate change technology and solutions that international universities and companies. We have 6,000
can transform the society into a low-carbon economy. dedicated students, who are preparing themselves for
As a top-level university, DTU is committed to finding the future and 4,500 staff members, who share the
these solutions. Our unique know-how of the technical common goal of providing education, research, public
and natural sciences is in high demand through-out the sector consultancy and innovation in order to increased
world. We also collaborate with leading national and growth and welfare. Read more on www.dtu.dk

12

Being in tune reduces
fuel consumption
Auto-tuning ensures that the com- years of engine running. In comparison, ed 2 million tons. This is equivalent to
bustion process of a MAN Diesel a standard car engine will, in its lifetime, 5 million tons of CO2, or about 10% of
engine is always optimized. This al- not run much more than a total of one the total annual Danish emission of CO2.
lows for continuous adaptation to year.
wear, changed fuel properties and The developed engine control system 5HWUR¿WWLQJ ZLWKRXW GRFNLQJ
operating conditions. The result is a constantly monitors and compares the The Auto-tuning system is simple to install,
reduction of fuel consumption, CO2 measured combustion pressures to the DOVR DV UHWUR¿W RQ YHVVHOV DOUHDG LQ VHU-
emissions and particulates. reference value. Hereafter, the control vice. Installation does not require docking
system will automatically adjust the ti- but can be done while in normal service.
Today, tuning of the engine performance ming of the fuel injection in accordance
is a process done manually by the ma- with the deviation between the measured Pay-back time is estimated to 5 - 20
rine engineer. Typically, it takes some value and the reference value. This is months of operation, depending on en-
hours once a month or whenever re- done in order to reach the optimal com- gine size and operation schedule. Thus,
quired, e.g. after engine overhaul. The EXVWLRQ SUHVVXUHV GXULQJ WKH QH[W ¿ULQJV with the MAN Diesel Auto-tuning concept,
tuning will make the engine run safely shipowners are being offered an easy
within recommended load limits but still Being in tune redusces fuel con- way to reduce vessel operating costs and
leaves a margin for performance opti- sumption DW WKH VDPH WLPH FRQWULEXWH VLJQL¿FDQWO
mization as operating conditions and The constant and automatic tuning to best to the reduction of CO2 emissions.
fuel oil properties change over time. engine performance allows for continu-
ous adaptation to wear, changed fuel oil
With Auto-tuning, this margin can be properties and operating conditions, e.g.
harvested by continuously and au- sailing in cold or warm climate. This offers Project facts
tomatically tuning the engine for D ZLGH UDQJH RI EHQH¿WV QDPHO UHGXF-
best performance, a task that is tion in fuel consumption, CO2 emission Category: Machinery
not feasible to be done manually. and carbon particles, as well as reduced
maintenance costs and risk of damage.
Constant measuring and tuning
The Auto-tuning concept is based on The reduction in fuel consumption for the CO2 1-3 %
online measurements of the combustion average vessel is expected to be above NOX 1-3 %
pressures in the cylinder chambers. This 1%, whereas some vessels will have a SOX 1-3 %
is an extremely harsh environment for potential of more than a 3% reduction.
a sensor to function in as the exhaust Partners:
gas passes with high temperature and If Auto-tuning is installed on the more
A.P. Moller-Maersk
at high pressure. However, sensor tech- than 10,000 MAN Diesel two-stroke en-
nology has reached a point that allows gines in service world-wide, the total fuel MAN Diesel
for constant measuring for more than 4 consumption will be reduced by estimat-

Environment
is our business, too
Greenhouse gas emissions are global challenges that call for global measures. Our efforts have resulted in a 2.4% CO2 reduction in
solutions. NORDEN welcomes any demands that support environ- 2008 and a further 3.3% reduction year to date. We see an
mental improvements and ensure equal competition for shipping additional 4.5% reduction potential through better trimming of
companies around the world, but we also believe that quality ship- our ships and up to 26% reductions through just-in-time transports
ping companies should make a contribution themselves and make in the future.
environment part of their business. We do so at NORDEN.
All of this not only benefits the environment, our customers and our
We work to further reduce fuel consumption and emissions from employees – it’s also sound business. We see sustainable
our ships through higher efficiency of our engines, trimming of solutions in all these areas as key.
the ships, careful route planning, slow steaming and a list of other

Visit us at: www.ds-norden.com

13

ABB turbocharging reduces
fuel consumption, CO2 and NOX

$%% 7XUERFKDUJLQJ KDV UHWUR¿WWHG control the light entering a room through the ship is fully or partially loaded, on
MV Alexander Maersk with a new, a window; instead of controlling the the high seas or entering port, or has a
KLJK HI¿FLHQF WXUERFKDUJHU $V light, VTG employs adjustable vanes tail wind or a head wind, for example.
ZHOO DV GLUHFW EHQH¿WV LQ IRUP RI UH- ahead of the turbocharger turbine to
duced fuel consumption and emis- vary the amount of exhaust gas reaching Thirdly, the Alexander Maersk has one of
sions, the turbocharger’s variable WKH WXUELQH ¿JXUH

WKH ¿UVW ODUJH PDULQH HQJLQHV WR EH ¿WWHG
turbine geometry is an ‘enabling ZLWK ([KDXVW *DV 5HFLUFXODWLRQ (*5

IRU
technology’ of the ship’s exhaust This controls turbine speed and allows NOX emissions reduction. EGR recircu-
gas recirculation system. variations in the amount of air com- lates the engine exhaust gases back into
pressed by the compressor. Under elec- WKH FRPEXVWLRQ FKDPEHU WR LQÀXHQFH WKH
A turbocharger is a small radial fan pump tronic control, the quantity of air entering burning of the fuel in the air and thus
driven by the energy of the exhaust gas- the engine cylinder is closely matched to the formation of NOX. Close control of
es of an engine. The purpose of a tur- the amount of fuel injected into the com- the quantity of air entering the engine
bocharger is to increase the density of bustion chamber. As stated above, the LV WKXV HVVHQWLDO IRU HI¿FLHQW (*5 $%%
air entering the engine to create more right amount of air + the right amount of Turbocharging’s VTG system is the ideal
power. By increasing the amount of air IXHO HI¿FLHQW FOHDQ FRPEXVWLRQ technology to achieve this control.
reaching the combustion chamber, the
engine can burn fuel more completely. 7ULSOH %HQH¿WV
This offers some obvious advantages The installation of the ABB type A175- 2
as more complete combustion results in L turbocharger with VTG technology on
increased power, producing fewer emis- the engines of the Alexander Maersk has 1
sions. WKUHH PDMRU EHQH¿WV

The overall effect is more power for a )LUVWO WKH RYHUDOO HI¿FLHQF RI RQH RI
given engine size, lower fuel consump- the most modern and advanced tur- 3
tion for the work done by the engine and bochargers in the world results in 4
reduced noxious emissions. Since marine VLJQL¿FDQW LPSURYHPHQWV LQ WKH HQ-
Figure 3
engines burn hydrocarbon fuels, lower gine’s fuel consumption and the for-
fuel consumption automatically means mation of oxides of nitrogen (NOX

lower emissions of the greenhouse gas
carbon dioxide for the amount of freight Secondly, close matching of the amounts
transported. of combustion air and fuel means very
HI¿FLHQW FRPEXVWLRQ DQG YHU FORVH DOLJQ-
5HWUR¿WWLQJ ment of the power the engine produces
Alexander Maersk to the power needed to propel the ship.
On the Alexander Maersk, ABB Turbo- The latter varies according to whether
FKDUJLQJ ¿WWHG WKH DGYDQFHG $/
WXUERFKDUJHU )LJXUH

IHDWXULQJ WKH
YDULDEOH WXUELQH JHRPHWU VVWHP 97*

HOW DO TURBO-
The functions of VTG can be compared CHARGERS WORK?
to the principles of Venetian blinds that Figure 2
As shown in Figure 3, turbochar-
gers use the energy in an engine’s
H[KDXVW

Project facts
located on the same shaft as a com-
SUHVVRU ZKHHO

7KH WXUELQH WKXV Category: Machinery
drives the compressor which forces Emission reductions:
DLU

LQWR WKH HQJLQH FOLQGHUV CO2
where it is further compressed. By NOX
increasing the amount of air reach-
ing the combustion chamber, the
engine can burn more fuel more Partners:
completely. A.P. Moller-Maersk
ABB
Figure 1

14

Emission reduction using
exhaust gas recirculation

MAN Diesel has developed an Ex- ces the oxygen content of the air in the the International Maritime Organisation’s
haust Gas Recirculation (EGR) sys- combustion chamber, thereby reducing ,02

IRUWKFRPLQJ UHTXLUHPHQWV IRU 12[
tem for low-speed two-stroke en- the combustion temperature. The lower emissions with EGR alone.
gines, which can reduce harmful combustion temperature results in a re-
NOX emissions from ships by 80%. duced formation of NOX. In addition to EGR process tests in Co-
Tests carried out on MAN Diesel’s test penhagen, it is necessary to assess the
The newly developed EGR system re- engine in Copenhagen have shown very effect of EGR on the engine over a pe-
duces harmful NOx emissions by direct- promising results with EGR techno- riod of time, particularly with the use of
ing part of the exhaust gas back into the logy on a two-stroke engine. The results Heavy Fuel Oil which contains sulphur
scavenge air of the engine. This redu- show that it is possible to comply with and is the most common form of fuel on
low-speed two-stroke marine engines.
A. P. Moller - Maersk is participating in a
development partnership by providing a
ship for a service test of the prototype
EGR system. The prototype EGR system
is being installed on the container ship
Alexander Maersk from July 2009 to Ja-
nuary 2010, and once the installation is
complete, the EGR system will be put
into service until the end of 2010.

There are great expectations towards
the EGR system. Especially in light of the
new emission rules set by IMO, coming
into force in 2016, whereby NOX emis-
sions must be reduced by 80%. MAN
Diesel has led the initiative in develop-
ing emission reduction technologies. The
(*5 VVWHP LV WKH ¿UVW RI LWV NLQG WR EH
installed on a ship.

Project facts

Category: Machinery
NOX 80%
SOX 19%

Partners:
A.P. Moller-Maersk
Aalborg Industries
MAN Diesel
Odense Steel Shipyard

15

From complexity to
opportunity
0DQ GLIIHUHQW IDFWRUV LQÀXHQFH WKH When a 200 meter long ship is propelled GreenSteam achieves this through
fuel economy of a large ship, and in through the sea by a 10.000 kW engine, advanced mathematical modelling of
combination these factors create a it is not an easy task to calculate the the complex realm of ship fuel economy.
very complex system. GreenSteam resulting speed. The direction and All of the involved factors are measured
is a new solution made to handle speed of winds and waves, the loading and recorded over a long period
this complexity in order to achieve of the ship and the angle of the rudder of time. for some of these factors,
the best possible fuel economy for are some of the factors that affect the specially adapted sensors are used to
large ships amount of resistance that the ship must capture the necessary information.
overcome. Some factors, such as the This comprehensive data collection is
propeller settings – typically revolutions then ‘fed’ to the GreenSteam software
per minute – and the ship’s trim, can be which is able to observe and correlate
controlled by the crew, but many factors the interplay and patterns that exist in
relate to systems only manageable the data. This means that instead of
through complex calculations. calculating your fuel economy based on
D ORQJ UDQJH RI VLPSOL¿HG DVVXPSWLRQV
Yet, all these factors interact. For you use the actual data from the
instance, if the ship is fully loaded, a individual vessel.
greater part will be submerged than
when the ship is partly loaded. The optimal controls are dynamically
calculated by GreenSteam and displayed
Adjusting the controllable factors on the bridge through a carefully
so that the fuel economy of the designed user interface that allows the
ship is optimized is therefore a very captain to quickly and easily determine
complicated problem, and even more any needed adjustments.
so when adding non-constant factors
such as wind direction and speed. GreenSteam is currently being operated
on board one of Damskibsselskabet
An exciting opportunity NORDEN A/S’s tanker vessels. Current
At the same time this presents a great estimates indicate that this vessel
opportunity. If the controllable factors can improve fuel economy by around
can be adjusted correctly to the ship’s 4 percent. Such an improvement
changing conditions, it will be possible to corresponds to a reduction in annual
LPSURYH WKH IXHO HFRQRP VLJQL¿FDQWO CO2 emissions of roughly 1,200 metric
tons and reduces annual fuel costs by
Project facts around €100,000.

Category: Operation
CO2 4%
NOX 4%
SOX 4%

Partners:
GreenSteam
Norden

16

Without a green consciousness
there can be no Green Ship
- and no quality shipping
At SIMAC, we educate and train natural focus on optimization and energy This combination of theory and practice
PDULWLPH RI¿FHUV FDSDEOH RI VDLOLQJ HI¿FLHQF $Q XQGHUOLQJ FRQVFLRXVQHVV RI puts SIMAC students in the borderland
and operating ships with a constant our climate ensures that the environment between maritime research and the
focus on optimization and energy is automatically taken into consideration maritime industry. Their systems of
HI¿FLHQF EXW RI HTXDO LPSRUWDQFH whenever a routine, process or operation terminology cover both areas, and
we educate future maritime is carried out on board a ship or planned WKLV PDNHV WKHP SDUWLFXODUO TXDOL¿HG
leaders capable of handling and supervised ashore. as the connecting link between the
management issues ashore. two entities. Not only do they possess
Covering both theory and practice the theoretical insight necessary to
When SIMAC students pass their understand the research, they are also
Green Ship of the Future is the vision ¿QDO H[DP WKH SRVVHVV WKLV YHU capable of operating the technological
of a shipping industry that is green in consciousness of green shipping. It has solutions resulting from the research.
the sense of being sustainable. The grown from the polytechnic learning And continuously they contribute to the
primary purpose of the project is to environment they have been trained in. further development of the very same.
develop green ships that – by virtue Graduating with a professional bachelor
RI HQYLURQPHQWDO DQG HQHUJHI¿FLHQW degree, each and every one of our To illustrate the fruitful collaboration, one
technology – contribute to reducing the students has learned to adopt a critical- can imagine a group of cadets performing
harmful emissions caused by shipping. UHÀHFWLYH SHUVSHFWLYH RQ WKH YHU SUDFWLFH experiments and measurements for
they participate in. They are trained to use in a research project initiated by a
However, sustainability is not achieved by challenge what others might take for university or a shipping company. The
HQHUJHI¿FLHQW WHFKQRORJ DORQH *UHHQ granted. And to do so systematically. UHVHDUFKHUV SUR¿W E WKH HPSLULFDO GDWD
WHFKQRORJ LV GH¿QLWHO D QHFHVVDU EXW produced by the students. In return,
QRW QHFHVVDULO D VXI¿FLHQW FRQGLWLRQ But at the same time – and not less the students gain an insight into the
for cleaner shipping. Only when the importantly – SIMAC students graduate methods of research, and at the same
technology is operated by a person with with a massive amount of practical time they collect data that can be used
a green consciousness does it come up to experience. During their training as the empirical foundation for their own
its full potential, because only then it will as cadets on board ships, they are theoretical projects. In the long run, the
be operated in accordance with its design. continuously working with environmental collaboration helps qualify the students
DQG HQHUJHI¿FLHQW WHFKQRORJ ± IRU to become the world’s best maritime
Green consciousness instance when collecting relevant data leaders.
Due to their education, the next generation for use in research, product development
of maritime leaders has developed a or the like.

Project facts
Category: Operation
CO2
NOX
SOX
Partners:
DCMT
SIMAC

25

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Driving sustainability
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Today with questions of sustainability being asked of all industries in the face
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its CO2 emissions. NanoNord A/S, J.Lauritzen and Lloyd’s Register are working
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international shipping better manage its fuel resources and reduce emissions.
Learn more about Lab-On-A-Ship™ – go to www.nanonord.com

26

System integration and
waste heat utilization

A group of Danish and Swedish driven boiler while sailing but only when two years. The installation is a onetime
companies has discovered a new the ship is not using the main engines. expense, whereas the savings can be felt
way of saving 8 tons of oil per day Calculations show that 8 tons of oil is immediately and will last through the 20-
by utilizing existing components in saved each day from a ship with a normal 30 years the ship is expected to last. 8
75,000 tdw tankers. use of 42 tons of oil per day. This means PHWULF WRQV RI RLO SHU GD LV D VLJQL¿FDQW
that a lot of oil and money can be saved amount of money saved per year. On top
Modern diesel engines have high energy each year.’ of this, the ship becomes less vulnerable
HI¿FLHQF EXW WKHUH LV VWLOO D ORW RI ZDVWH to any new environmentally related
heat to be utilized. In this project, Can be installed in two weeks WD[HV GXH WR WKH VLJQL¿FDQW DPRXQW RI
the possibility of using the waste heat LR Marine is a company specialized in oil saved.’
from the main engine to heat up the constructing and installing the piping
cargo areas aboard the ship has been on the top decks, mainly on large By stopping the waste of energy, the
investigated. The initial analysis shows tankers. They are currently cooperating environment is helped as well. The oil
that it is possible to save up to 20% of with the specialized pump producing saved means that the CO2 emission
the yearly fuel consumption, and thereby company DESMI and the producers of LV UHGXFHG E D VLJQL¿FDQW DPRXQW
saving both money and CO2 emissions. heat exchangers, APV. The cooperating Calculations show that the 8 tons of oil is
companies are mainly focusing on ideas the equivalent of 24 tons of CO2 emission
John Nielsen, Global Sales Manager at from the technical manager of the per day, meaning that the new system
LR Marine, explains, ‘We’ve taken the Swedish ship owning company Marinvest, will help the global environment.
existing system and changed the outlet Roger Karlsson, who brought several
for the cooling water. This happens by issues to the companies’ attention. If Talk and brainstorming
LQVHUWLQJ D PRGL¿HG KHDW H[FKDQJHU Marinvest accepts and implements the The basic idea for all this came from a
between the existing components, system in its modern ships, new piping, quite common conversation at a marine
channelling the heat from the water into heat exchanger and pumps will have to convention, which quickly turned into a
the supporting systems on the ship. This be installed. Also all pipes have to be creative brainstorming process resulting
provides heat for the cargo tanks, bunker insulated to minimize the loss of heat. in a way to stop a tanker from using the
tanks, accommodation and such systems, boiler while the ship was sailing, while still
and furthermore provides the heat and John Nielsen explains, ‘For a 75,000 tdw maintaining all systems. The participants
energy for all the supporting elements tanker, the new system can be installed quickly realized that this system could
of a ship while under way.’ John Nielsen in two weeks. The current calculations be implemented directly on new tankers
continues, ‘This basically means that show that the investment by a shipowner without any changes to the basic design.
a ship of this size does not need an oil in this system will have a payback time of

Project facts

Category: Machinery

CO2 20 %
NOX 20 %
SOX 20 %

Partners:
APV
DESMI
LR Marine

27

Advanced fuel saving made Simple
www.decision3.com/greensteam

Emma Mærsk e world’s largest container ship Emma Mærsk belongs to one of
Hong Kong the industry’s youngest and most fuel-eﬃcient ﬂeets.

anks to our shipping history and global reach, we know
this planet like few others. at is why we not only believe
in the business and environmental advantages of
sustainabili - we act on them.
www.maersk.com

Headquartered in Copenhagen, the A.P. Moller - Maersk Group includes
Maersk Line, Maersk Oil and a number of other companies within shipping,
oil, logistics and retail, employing 120,000 people in 130 countries.

DESMI pumps
integrate
knowledge technology

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Tagholm 1 - 9400 Nørresundby - Denmark - Phone: +45 9632 8111 - Fax: +45 9817 5499 - E-mail: marine@desmi.com - web: www.desmi.com

28

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