NANOTECH KEY TO EGR AND CO2 REDUCTION ADVANCES

from The Motorship April 2023

SUBSIDIES & ELECTROLYSER SPREADS HIT METHANOL PLANS

FuelSave, the Germany-based technology developer behind the FuelSave+ combustion optimisation product, is in the process of patenting a new development for exhaust gas recirculation (EGR) solutions, breaking new grounds in emission reduction to not only reduce NOX emissions but also reduce CO2 emissions in an after treatment process

8 Sima added that FuelSave was also in the ﬁnal stages of developing two types of CO2 reduction solutions, which it plans to use to extend the emissions reduction potential of its EGR+ concept

The company has successfully completed trials for a combination of FS MARINE+ with an EGR add-on and demonstrated IMO tier III compliance, installed on a fourstroke test engine at FVTR Gmbh’s large engine test centre in Rostock in Germany. FuelSave’s CEO, Marc Sima, told The Motorship that the week-long full-engine trial had been conducted on a 6M20 over the entire load range.

“The EGR add-on works as an enhanced exhaust gas recirculation (EGR) with a lower recirculation rate due to the already reduced NOx emissions from the water and methanol injections, addressing challenges such as sooting that typically aﬀect an EGR system.”

The test had been conducted by FuelSave as a performance validation, and the technology developer is in the process of patenting further evolutions of the system with a novel innovative injection and aftertreatment solution that uses nanotechnology in the EGR system, which will be put on the testbench as well in the near future.

Interestingly, the next generation EGR advance relies on nanotechnology advances to improve the eﬃciency of the NOx reduction (see Nanotechnology Solutions). Sima notes that in addition to improving the reduction of the primary fuel being used, the system is also capable of actively reducing the CO2 emissions to break new grounds in decarbonisation.

This advance, which Sima describes as “state of the art for emissions reduction”, is extremely timely ahead of the extension of the EU’s Emissions Trading System to the maritime sector in 2024, and IMO-level discussions about the potential introduction of a carbon levy. “Our solution is being developed at just the right moment as ship owners and operators are focusing on reducing their CO2 and CO2e emissions.”

The potential of the solution to reduce CO2 emissions had been validated in lab scale tests, which had demonstrated “very sizeable” CO2 emission reductions. Sima noted that the company was developing a version of the solution that is aiming to achieve up to 75% CO2 reduction. Although FuelSave’s FS MARINE+ solution had been approved for use with a number of diﬀerent 4-stroke manufacturers engines, Sima was keen to note that the EGR add-on will also be applicable to customers in the 2-stroke market, as well as the 4-stroke market.

Sima noted that “an EGR is a passive solution, so you avoid some concerns related to engine test validations and enable a very exciting retroﬁt pathway” and is keen to collaborate with engine OEMs. “In fact, that is one of the reasons we focused in the FVTR test bench tests to ensure that the test results were incontrovertible.”

Synergies with FS Marine+

Although Sima noted that the EGR development was expected to lead to improvements in its NOx reduction performance, the solution already validated is creating synergies with Fuelsave’s FS Marine+ technology.

“We achieve synergies with our existing fuel injection solution by improving towards a cleaner combustion, and by controlling the temperature of the combustion to address some of the shortcomings of a typical EGR operation,” Sima said.

CO2 reduction module

Sima added that FuelSave was also in the ﬁnal stages of developing and validating two new types of CO2 reduction solutions, which it plans to use to extend the emissions reduction potential of its EGR+ concept.

“We are using nano base coatings and elements to improve the catalytic reaction for the reduction of CO2 in the exhaust gas stream of marine engines. We expect to be able to achieve a signiﬁcant reduction in CO2 emissions, which has obvious advantages for our customers from a CII perspective and in their decarbonisation journey.”

The ﬁrst trials of the CO2 solution have not yet been completed on the test bench, Sima noted, but the lab results are “extremely promising and exciting” and will provide one of the most exciting value adds to ship owners in the retroﬁt segment.

Sima noted that CO2 savings from 10-70% are feasible according to the lab results and simulations performed. The variation reﬂects the recirculation rate, as well as some of the product reﬁnements.

Potential LNG applicability

Fuelsave also anticipated that the initial focus of the research for the EGR+ and CO2 modules had until now been on MDO / MGO and fuel oil (VLFSO/HFO). However, the solutions would be applicable to alternative fuel types.

The low parasitic load of the catalytic module meant it might be an interesting alternative to reducing the methane slip produced by dual-fuel engines operating on LNG.

Sima also noted that methanol was another interesting business case as the solution would lead to a carbon sion for ings ance gine gas al in NOx nge,” is a PEX tical the

For example, FS Marine+ creates a NOx buffer which can be used to optimise engine efficiency by traditional means of optimising the cylinder pressures and ignition timing. The increase in NOx due to higher temperatures and pressures inside the cylinder is counteracted by the dynamic liquid injections with proven methods of water and methanol injections. FS Marine+ in combination with an EGR+ add-on further increases this ‘NOx buffer’ – enabling a new emission tier while providing additional optimisation potential for further increasing the overall efficiency and cost savings through lowering the fuel consumption.

The system allows operators to fulﬁl IMO Tier III compliance standards for reducing NOx emissions even at partial engine loads and DP3 operation.

“We know that there is strong interest from the oil and gas sector and also from the DP3 oﬀshore sector in general in emissions reduction technology that could maintain NOx emissions reduction performance across the load range,” Sima said. The new system operates at low loads, which is a known challenge for SCR systems, together with high OPEX through the catalyst consumables of an SCR and its logistical challenges along with its space requirements. “This is the basis of our value proposition against SCRs,” Sima said.

Nanotechnology Powered Breakthrough Solutions

Marc Sima noted that patents are pending for the nanotechnology that underpins both the EGR+ concept and the upcoming CO2 reduction module. The application of this technology with large bore engines would represent the ﬁrst such application in the world, Sima noted, as far as he knew, and represented an attractive value proposition for the industry.

Sima noted that FuelSave relies on external collaboration with leading nanotechnology scientists for the nanotechnology for the CO2 reduction technology, for which FuelSave has an exclusive licence in the maritime market. He expects to reveal further details about the technology by May 2023.

negative solution for green methanol, wheras as before it was merely circular. In addition, the catalysed syngases could be reinjected to further reduce primary fuel consumption, which would be a step towards even greater primary fuel savings and CO2 reduction

Marc FuelSa told Th that th has su compl a c M an EGR a 6M2 at FVT e Germa

Marc Sima, FuelSave’s ceo, told The Motorship that the company has successfully completed trials for a combination of FS MARINE+ with an EGR add-on, on a 6M20 test engine at FVTR Gmbh’s large engine test centre in Rostock in Germany marine engineering equipment •Bilge water monitors & ﬁltration •Seals and bearings •Dry dock services •Underwater repairs •Additives to prevent leakage

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