A QUANTUM LEAP The biggest change in energy efficiency since the - - PDF document

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A QUANTUM LEAP The biggest change in energy efficiency since the - - PDF document

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16.02.2016 A QUANTUM LEAP The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery Jon ge Eidem, Ulmatec 16.02.2016 ULMATEC Ulmatec Handling Systems AS, Hareid, Norway Ulmatec Components AS,

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A QUANTUM LEAP

The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery Jon Åge Eidem, Ulmatec

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Ulmatec Handling Systems AS,

Hareid, Norway

Ulmatec Components AS,

Hareid, Norway

Ulmatec Skipsservice AS,

Fosnavåg, Bergen, Tromsø, Norway

Ulmatec Pyro AS,

Gamlem, Norway

Ulmatec Engineering AS,

Hareid, Norway

Ulmatec Baro AS,

Fosnavåg, Norway

Penetrators Norge AS,

Stavanger-Ulsteinvik, Norway

  • Penetrator Inc.

Canada, North America

Ulmatec Asia Pte Ltd

Singapore

Ulmatec Well Products As,

Stavanger, Norway

Powder Tec AS,

Surnadal, Norway

Ulmatec Services LLC

Dubai, UAE

Ulmatec Baro LLC

Houston, North America

16.02.2016

ULMATEC

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MORE THAN 60 YEARS OF KNOW-HOW

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Pyro founder Palmar Bjørnøy Cold trips to Shetland – 1940 - 1945

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MORE THAN 15.000 SHIPS WORLDWIDE WITH PYRO™ HEATING SYSTEMS

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ÅRETS BEDRIFT MØRE OG ROMSDAL 2014 ÅRETS NYSKAPAR NORDVESTLANDET 2015

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Our focus and promise since 2011 … recovering otherwise wasted energy instead of using high- grade energy in the form of oil or gas

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60% OF ENERGY CAN EASILY BE UTILISED

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ONLY 30-40% OF ENERGY IS USED EFFICIENTLY

In 2011 we claimed

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Now, in 2015, we know that

CAN BE UTILISED

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PYRO™ WASTE ENERGY MANAGEMENT SYSTEM

A QUANTUM LEAP

16.02.2016

The most important energy saving invention since moving from steam engine to diesel engine

Steam engine

1800 - 10-15% efficiency / utilisation

Diesel engine

1900 - 30-40% efficiency / utilisation

Diesel Engine + Waste Heat Recovery

2011* - 40-60% efficiency / utilisation

Diesel Engine + Waste Energy Management 2015** - 60-75% efficiency / utilisation

* In 2011 Ulmatec Pyro introduced the Pyro™ Waste Heat Recovery System ** In 2015 Ulmatec Pyro introduced the Pyro™ Waste Energy Management System

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RUN YOUR HEATING, COOLING AND POWER SYSTEMS AT MINIMUM COST

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We see a great many opportunities for huge savings by transferring energy consumption from electricity to waterborne heat… … even generating electric power from waste heat recovery

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MADE POSSIBLE WITH PYRO™ SYSTEMS

Fuel Fired Heater Exhaust gas Economiser Incinerator System Waste Energy Recovery System (patent) Tank Heating System (patent)

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Traditional products New products 2012-2013

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MADE POSSIBLE WITH...

GREEN TECHNOLOGY from ULMATEC, SPERRE & ANDA OLSEN

SPERRE Pleat & Rack Coolers with their uniqe competence and low pressure drop. ANDA OLSEN battery technology for energy storage and peak operations together with CLIMEON De-Icing System (patent) Ballast Water Management System (patent) Waste Energy Cooling System (patent) Waste Energy Power Generation System (patent) Waste Energy Management System (patent)

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New products 2015-2017

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UNDERSTANDING THE ENERGY CONVERSION

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kW 2500

36,6 %

830

12,2 % 2478 36,3 % 59,7 % 763 11,2 % 161 2,4 % 91 1,3 %

6823

100,0 %

L/h kg/h

kg/kWh 100 % 656 564,16 0,226 75 % 510 438,60 0,234 50 % 372 319,92 0,256

kW Load

43539

6823 100 % 45000 Caterpillar 3516C (data from engine supplier) Engine load Fuel energy Fuel energy KJ/s (kW)

  • Max. Specific Fuel value KJ/kg

Rated power Heat rejection to coolant Heat rejection to exhaust gas Heat rejection to charge air aftercooler Heat rejection to air from engine Heat rejection to air from generator Total effect Engine load Fuel consumption Engine load

NOx kg/year

Effekct Energy/24h Consumption kW kwh kg/kWh *3) kg/kg *1) USD/kg *2) USD/liter kg/liter KJ/kg NOx tax USD Fuel USD Total USD Engine < 200 rpm (Generator) 1250 30000 0,256 0,1000 2,40 0,86 43539 672 768

  • 672 768

280 320 Engine 200-1000 rpm (Generator) 1250 30000 0,256 0,0530 2,40 0,60 0,86 43539 356 567 1 955 721 2 312 288 148 570 Engine 1000-1500 rpm (Generator) 1250 30000 0,256 0,0500 2,40 0,60 0,86 43539 336 384 1 955 721 2 292 105 140 160 Engine >1500 rpm (Generator) 1250 30000 0,256 0,0440 2,40 0,60 0,86 43539 296 018 1 955 721 2 251 739 123 341 Fuel fired heater (MGO) 1250 30000 0,091 0,0036 2,40 0,60 0,86 43539 8 609 695 198 703 807 3 587 Heat recovery 1250 30000

  • Energy Cost

Nox Cost Fuel

*1)= kg Nox / kg fuel Engines (200-1000kW og >1500kW) before year 2000, Nox value increase 0,001 kg/kg *2)= USD/ kg. Nox (19,19NOK/8,00USD/NOK=2,40 USD/kg) *3)= Engine speciffic values to be used (e.g. 0.256 g/kWh) *4)= Spesiffic density MGO 0,86 kg/liter

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FUEL SAVINGS

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Engine Installation 5xCaterpillar 3516C 12500 kW Average Engine load 2x50% 2500 Available Waste Energy effect @ 100% engine load 3200 kW Actual available Waste Energy effect @ 50% engine load 1250 kW Crew 120 Ballast Water capasity 5000 m3 Installed cooling effect 15000 kW Operational hours 8760 h Energy efficiency 0,256 kg/kwh Desity fuel 0,86 kg/liter

Effect kW Energy kWh Effect kW Energy kWh Effect kW Energy kWh Heating of accomodation

  • 150

1 314 000 250 2 190 000

Cooling of accomodation

150 1 314 000 50 438 000

  • Fresh Water Production

200 1 752 000 300 2 628 000 400 3 504 000

Sanitary Hot Water

25 219 000 45 394 200 50 438 000

Tank Heating

  • Tank Washing
  • De-Icing
  • 1000

8 760 000

Ballast Water Treatment

  • Pre-heating of engine at standstill

25 219 000 40 350 400 50 438 000

Total waste energy used

400 3 504 000 585 5 124 600 1750 10 950 000

Fuel Fired Energy

500 4 380 000

Available waste energy

850 665

Electricity production 10% efficiency

85 744 600 66,5 582 540

  • Fuel savings (Liter)

1 264 700 1 698 870 1 955 721

Total Fuel Consumption (Liter)

6 519 070 6 519 070 6 519 070

Total Fuel Saving

19 % 26 % 30 %

Avearage consumption/year Tropical Area Northern Area Artic Area

Offshore Vessel 120mx22m

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Example of benefits

= 2000 LITRE

Marine gas oil price is going up and down. Currently the cost is about US$500 per tonne and has been up to US$ 960 per tonne, but is expected to increase toUS$1,800 by 2020, and to US$2,300 by 2035

REDUCED PUMP EFFECT FUEL/YEAR

Source: Article by Chad Henderson, Wallenius Wilhelmsen Logistics, October 2014. Adjusted for current prices (September 2015).

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PYRO™ WASTE ENERGY COOLING SYSTEM

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Fixed rpm Frequency controlled Frequency controlled Fixed rpm

4 3 2 1

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PYRO™ WASTE ENERGY COOLING SYSTEM FUEL SAVING: 800.000 kWh = 200.000 LITRE FUEL/YEAR

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Example Traditional WECS

Cooling effect:

15.000 kW 15.000 kW

Pump capacity:

4x800m3/h 6x400m3/h

Pumping effect:

4x100 kW 6x50 kW

Energy Consump. 2 pumps: 1.600.000kWh 800.000kWh

PLATE HEAT EXCHANGER (PHE) SPERRE PLEAT COOLER

240 MAN-HOURS 1 MAN-HOUR 45 GASKETS 50 DAYS OFFHIRE 1 GASKET 1 DAYS OFFHIRE

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Energy saving solution

Fuel savings - Emission reductions

Rack cooler have no marine growth due to CuNi 90/10 and antifouling paint Reduced energy consumption on the seawater-pumps due to low pressure drop Chilled water element reduces running time at the chilled-water compressors Heat recovery element makes it possible to use the surplus heat

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PYRO™ WASTE ENERGY COOLING SYSTEM

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= 200.000 LITRE

Four pumps with automatic regulated valves which only pumps the required volume and flow of cooling water. Reduced number of pumps saves energy. A flexible system that works.

REDUCED PUMP EFFECT FUEL/YEAR

Fixed rpm

4

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PYRO™ COOLING SYSTEM BENEFITS

Reduced no. of cooling pumps installed Reduced no. of cooling pumps running Full control of cooling temperatures Reduced no. of heat exchangers installed Full control of circulation pressure Possible to utilize the waste low temperature (LT) cooling energy Full flexibility in no. of cooling pump running (automatic start/stop) Less energy used for cooling water circulation Monitoring the waste energy utilized - and wasted to sea and air (exhaust)

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CASE STUDY – INSTALLATION

140m Offshore Construction Vessel DP3-4 split power system

  • No. of seawater (SW) cooling pumps reduced from 30 to 12

reduction = 18

  • No. of freshwater (FW) cooling pumps reduced from 26 to 12

reduction = 14

  • No. of seawater heat exchangers reduced from 20 to 8

reduction = 12

  • No. of freshwater heat exchangers increase from 0 to 4

increase = 4

A minimum of cooling pumps running according to cooling requirement

In DP mode: 2-8 SW cooling pumps + 2-8 FW cooling pumps running Normal mode: 1-8 SW cooling pumps + 1-8 FW cooling pumps running

Full flexibility and back-up capacity DNV GL verified solution Significant reduction in engineering time Significant reduction in installation time Standardised and modulated “plug and play” units

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PYRO™ WASTE ENERGY MANAGEMENT SYSTEM

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HT circuit 85C-95C Cooling water 0C – 35C

EMISSION-FREE ELECTRICITY

EGB

Product range from 150kWe to 600kWe

PYRO™ WASTE ENERGY POWER GENERATION SYSTEM

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PYRO™ WASTE ENERGY POWER GENERATION SYSTEM

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1300kW WASTE ENERGY ELECTRIC POWER

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ANDA PRODUCTS

  • Batteries
  • System solutions
  • Motors & drives
  • Hybrid systems
  • Converters
  • AC UPS systems
  • DC UPS systems
  • Power supplies
  • Chargers
  • Inverters
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WASTE ENERGY POWER GENERATION SYSTEM BENEFITS

Converting engine waste heat to electricity (jacket cooling and exhaust) World record efficiency, twice as high as competing technologies Up to 5% fuel savings per annum Significant emission reductions Attractive payback times despite low oil prices Marine proven Remote diagnostics with

Live™

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PYRO™ - WASTE ENERGY MANAGEMENT SYSTEM

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Smart, flexible and cost effective

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A B

HEAT COMSUMERS

  • Air handling units
  • Fresh water generators
  • Tank heating system
  • Tank washing system
  • De-icing
  • Ballast water treatment
  • Electric power generation

UNITS TO BE COOLED

  • Engine high temp cooling
  • Engine low temp cooling
  • Thrusters
  • Provision plant
  • Electric equipment
  • Chill water
  • Propulsion motor / gear
  • Hydraulic equipment

A A B B B B B B ① Fuel Fired Heater ② Exhaust Gas Economiser ③ Split valves ④ Flow control units ⑤ High temp heat recovery heat

exchanger

⑥ Fresh water cooling pumps ⑦ Sea water / fresh water heat exchangers ⑧ Sea water cooling pumps ⑨ Expansion tank ⑩ Circulation pumps

COMPONENTS WERS -

WASTE ENERGY RECOVERY SYSTEM

WECS -

WASTE ENERGY COOLING SYSTEM

WEPG -

WASTE ENERGY POWER GENERATION

WEMS –

WASTE ENERGY MANAGEMENT SYSTEM

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SUMMARY ENERGY UTILISATION

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Utilized in engine

35%

Waste energy from exhaust system

12%

Waste energy from HT cooling system

13%

Waste energy from LT cooling system

10%

Utilised in Climeon system

5%

TOTAL

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QUESTIONS TO OUR BRAVE CLAIM?

A QUANTUM LEAP

The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery Jon Åge Eidem, Ulmatec

16.02.2016