CAPEX, OPEX and ROI calculations of different solutions
By aid of our software “ECA design”, we can calculate the cost of different solutions such as the open loop, hybrid or semi-hybrid design. The program has some selectors, which makes it easy to connect (or disconnect) the auxiliary engines and the oil-fired boiler to the scrubber. The CAPEX estimate will include both the scrubber price and the yard cost and is based on detailed costs from many different sub-suppliers. The OPEX calculations will include the additional fuel consumed due to the additional backpressure on the engines, the electrical power for running the scrubber as well as the lower heat value of HFO relative to compliant fuel. Several different scenarios are usually calculated for e.g. different fuel prices, fuel consumptions and if e.g. the discharge of open loop water is further banned in the future. Based on these calculations and an initial assessment about the space available onboard, the optimal system can be selected.
Reducing the pressure drop and water flow
Many scrubbers are running with an excessive waterflow or pressure loss because the suppliers have not had time to optimize the design and the automatic control of the pumps and water sprayers to exactly your engine and typical load profile. By aid of our software “ECA performance”, we can quickly access your scrubber log data (in almost any file format) and explore how well your scrubber is running relative to a “normal scrubber”. Based on this analysis and our recommendations, the scrubber supplier can usually upgrade the software controlling the scrubber.
Minimizing pressure drop in the exhaust gas channels
A proper design of the exhaust gas pipes is important to minimize the engine backpressure. However, as space is often restricted, it is often necessary to squeeze the pipes and manifolds in some directions. By aid of CFD, we can locate possible “bottle necks” and usually reach a fair compromise between pressure drop, design, dimensions and cost.
Design of funnel exit
The funnel exit is sometimes designed with a too large diameter whereby the gas isn’t lifted probably away from ship. Consequently, water droplets and soot might drop down on the deck and in worst case, the exhaust gas might be sucked back to the engine. By aid of our droplet catcher design we can reduce the risk of such problems. We can also predict the plume flow pattern by aid of CFD.
Advanced data analysis of scrubber data
It is required to log the scrubber data every 4th minute according to the MEPC guidelines for exhaust gas scrubbers. Based on these data and by aid of our software “ECA performance”, we can visualize how the scrubber is operating and estimate some parameters in a model, which will make it possible to predict how the scrubber will perform under more extreme conditions. The model can also help to give an alert if a sensor seem to need calibration already before the legislative limits are reached. The model can also continue to predict the emissions in case of break-down of e.g. the gas or water analyzer (According to MEPC.1-Circ.883).
Many different problems might arise during or after the installation of a scrubber system. Sometimes it is just minor issues, which we might help to fix from distance in dialogue with the crew onboard. Sometimes, it is more serious issues which need ordering of spare parts and co-ordination of a technician to arrive in the next port. Often, we can help to diagnose the problem by asking the crew to forward the electronic log data from the scrubber PLC or by asking them to “try something” onboard. Once we know the exact problem, it is possible to order the spare parts and to arrange the right technician to fix the problem in the next port.
Sampling and analysis
Sampling and analyzing your scrubber water as required according to the IMO/MEPC guidelines.
Sampling and measuring the alkalinity of the seawater. This is important for the Sea Acceptance Test (SAT) to conclude if the SOx removal efficiency as specified at a certain alkalinity.
Sampling and analyzing the content of suspended solids (SS) in the water. This is particularly relevant for hybrid or closed loop scrubbers in order to find out how soot builds up in the water and how much soot the water cleaning system can remove.