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PureDry Waste fuel recovery Forum 25th April 2014 Dimitris Poulos ALFA LAVAL AEBE.

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Presentation on theme: "PureDry Waste fuel recovery Forum 25th April 2014 Dimitris Poulos ALFA LAVAL AEBE."— Presentation transcript:

1 PureDry Waste fuel recovery Forum 25th April 2014 Dimitris Poulos ALFA LAVAL AEBE

2 Waste fuel oil © Alfa LavalSlide 2

3 Waste fuel oil tank Recovered fuel from a 100 m 3 waste fuel oil tank could save you… USD 32,500 Content ?

4 Sources © Alfa LavalSlide 4

5 Up to 2 % of HFO is lost – The Sources © Alfa LavalSlide 5 Service tanks Automatic FO filters Injector pumps FO Purifiers

6 Waste fuel oil content © Alfa LavalSlide 6

7 © Alfa LavalSlide 7 Contents in the waste fuel oil tank Fuel oil Oil polluted water Suspended solids 45 – 55 % 55 – 45 % ~ 1 %

8 © Alfa LavalSlide 8 WFO 100 t 49,5% fuel oil 49,5% water 1% solids Finding out the content… 49.5 t Water (max 100 ppm oil) Fuel oil (max 60 ppm catfines) (max 1% water) 49.5 t Solids (appr. 7% catfines) 1.0 t (600 – 1000 ppm catfines) USD 32,500 Example

9 Rules & Regulations © Alfa LavalSlide 9

10 © Alfa LavalSlide 10 IMO MEPC.1/Circ.642

11 IMO MEPC.1/Circ.642 Slide 11 5 Definitions for the purpose of the Guidelines 5.1 Oily waste means oil residues (sludge) and oily bilge water. 5.2 Oil residue (sludge) means the residual waste oil products such as those resulting from the purification of fuel or lubricating oil from main or auxiliary machinery or separated waste oil from bilge water separators, oil filtering equipment or oil collected in drip trays, and waste hydraulic and lubricating oils.

12 IMO MEPC.1/Circ.642 © Alfa LavalSlide Re-generating fuel oil from sludge Oil residue (sludge) may be used onboard as re-generated fuel. Oil residue (sludge) is collected in an oil residue (sludge) tank prior to processing (disposal) back into the fuel oil system as re-generated fuel oil Oily drains should be recorded in the oil record book as any other oil residue (sludge) collection Re-generation of fuel oil from oil residue (sludge) should be an approved means of disposal of oil residue (sludge) according to the Supplement to the IOPP Certificate The re-generating process may include filtration, decanting or purification to remove unwanted heavy parts from the oil residue (sludge).

13 The waste fuel oil recovery process © Alfa LavalSlide 13

14 Waste fuel oil sources, examples Fuel automatic back flushing filters Fuel injection pumps Fuel separators Fuel settling & service tank’s bottom drains Tank coamings and cofferdams Boiler burner leakages Drip trays under fuel transfer pumps, etc. Pipe leakages Incident fuel spills Fuel oil waste tank cleanings © Alfa LavalSlide 14

15 Waste fuel oil collection Waste fuel oil is to be kept separate… © Alfa LavalSlide 15 Recovered lube oil is not acceptable as re-generated fuel for diesel engines due to high additive content …from waste lube oil

16 PureDry system © Alfa LavalSlide 16 Day tank Fuel Separators PureDry integrated process Clean fuel transfer pump FO transfer pump Fuel Conditioning System (Fuel filter etc) Settling tank Diesel Engines Primary Bilge water tank FO Drain tank Overflow tank Recovered fuel tank Other sources FO Main sludge tank Settling tank Bunker tanks - Boiler burner - Pump drip trays - Etc Waste fuel oil recovery Sludge pump Transfer Recovery Collection

17 © Alfa LavalSlide 17 Integration diagram WFR system PureDry system

18 The Sludge tank © Alfa LavalSlide 18

19 Capacity of sludge tanks © Alfa LavalSlide 19 MARPOL Annex I, Unified Interpretation of Reg When such ships are fitted with homogenizers, sludge incinerators, or other recognized means onboard for the control of sludge, the minimum sludge tank capacity (V 1 ) should, in lieu of the above, be: V 1 = 1m3 for ships of 400 gross tonnage or above but less then 4,000 gross tonnage, or 2 m 3 for ships of 4,000 gross tonnage and above.

20 The PureDry system © Alfa LavalSlide 20

21 © Alfa LavalSlide 21

22 Slide 22 XCavator Separator insert

23 The PureDry module © Alfa LavalSlide 23

24 © Alfa LavalSlide 24 Dosing unit & pump unit

25 References © Alfa LavalSlide 25

26 Frontline 40+ PureDry systems

27 © Alfa LavalSlide 27 Mediterranean Shipping Company 40+ PureDry systems

28 © Alfa LavalSlide 28 Wallenius Marine 4 PureDry systems

29 Stena 10 PureDry systems

30 Silja Line 1 PureDry system

31 © Alfa LavalSlide 31 Royal Caribean Cruise Line 1 PureDry system

32 © Alfa LavalSlide 32 “We expect to save K€ 100 the first year!” Christer Karlsson, Vice President, Newbuilding Norwegian Cruise Lines “We expect to save K€ 100 the first year!” Christer Karlsson, Vice President, Newbuilding Norwegian Cruise Lines “With coming regulations (e.g. Energy Efficiency Design Index) it’s becoming a clearer component!” Stig Björklund Team leader Hull & Machinery Norwegian Cruise Lines “With coming regulations (e.g. Energy Efficiency Design Index) it’s becoming a clearer component!” Stig Björklund Team leader Hull & Machinery Norwegian Cruise Lines 5 PureDry systems

33 PureDry marine references © Alfa LavalSlide 33 YearShip/Power plantOwnerShip type vessels (newbuildings)MSCContainer vessels (newbuildings)FrontlineTank vessels (newbuildings)StenaTank vessels (newbuildings)Wallenius MarineCar Carrier vessels (newbuildings)NCLCruise vessel (newbuilding)CCLCruise 2013Costa Luminosa (retrofit)Costa CrociereCruise 2013Norwegian Pearl (retrofit)NCLCruise 2013Navigator of the Seas (retrofit)RCCLCruise 2013Tor Fresia (retrofit)DFDS SeawaysRoRo 2012Silja Symphony (retrofit)Silja LineFerry

34 Case study – Silja Symphony Total main engine power: 33 MW PureDry installed at end of 2011 After one year approx 150 tons of fuel oil recovered Streams from process are put to: - Treated water: Bilge Holding tk - Recovered fuel: To bunker tanks - Dry solids: To shore as dry waste

35 Summary © Alfa LavalSlide 35

36 Operator benefits © Alfa LavalSlide 36 Up to 2% reduction in fuel costs 99 % reduction of oily waste volumes – minimal amount of solids for disposal ashore No additional waste generated Virtually eliminates oil waste handling costs Effective pretreatment of water prior to discharge to the bilge water tank Reduction in CO 2 footprint Low fixed maintenance cost Continuous mechanical warranty (MSE concept)

37 © Alfa LavalSlide 37 Installation benefits Smaller holding tank volumes, increasing payload capacity Compact modular design, for installation flexibility Easy to integrate with existing onboard systems

38 Savings © Alfa LavalSlide 38

39 Savings example 20 MW engine with different recovery factors

40 Savings example Different engine sizes

41 PurePay © Alfa LavalSlide 41 Note: PurePay is available for download from the PureDry site at Alfa Laval Share:

42 The End © Alfa LavalSlide 42


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