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자체 촉매기술로 컴펙트한 SCR 시스템 통합 솔루션 제공

Since 2011, we studied to develop the basic environmental technology and the services for green ships and power stations. Based on successful field tests, we have accumulated technical know-how on the eco-friendly technology to De-NOx, De-PM, CO/THC, sDPF and De-Sox treatment systems to our customers.

TECHNOLOGY OVERVIEW

Applications A leading company of emission control technology

Recently, environmental regulations for NOx and SOx, particles (dust), hydrocarbons, and even carbon monoxide are being strengthened not only on stationary plants but also on marine applications.
Hyundai Materials provide customized solutions with unique catalyst design and Envineering technology.
MARINE ENGINES
MARINE ENGINES

Coal Fired Boiler SCR Catalyst

Steel Works Incinerator

Cinerator De-NOx System

High Dust & Low Dust Applications

COAL FIRED POWER PLANTS
COAL FIRED POWER PLANTS

Marine SCR Systems

EGCS(Exhaust Gas Cleaning)

High Speed Engine Solutions

PM & NOx Removal Systems

ENGINE POWER PLANTS
ENGINE POWER PLANTS

Diesel Stationary Plants

Natural Gas Engines(LNG)

PM & NOx Removal

CO / THC / VOCs Removal

Marine EGCS

Exhaust Gas Cleaning System

EGCS (SCRUBBER)

According to MARPOL 73/78 'International Convention for the Prevention of Marine Pollution by Vessels', the International Maritime Organization (IMO) has agreed that all vessels operating in SECA (Sulfur Emission Control Area) have been required to use fuel with the sulfur content of 1% or less since July 2010 and to use fuel with the sulfur content of 0.1% or less since 2015.  Moreover, globally 0.5% or less in all oceans throughout the world is to take effect in 2020. In order to meet the requirements for permissible sulfur content in ship fuels, it is necessary to have a low sulfur content fuel or to have a desulfurization system that can meet regulatory requirements. Low sulfur fuels can be implemented in the short term. It will be the scrubber system that will meet regulatory requirements while using proprietary sulfur fuels.

Sulphur in Fuell
세계지도

Hyundai Materials EGCS

Hyundai Materials scrubber has a compact size that can minimize installation space constraint. Back pressure is minimized with its simplified internal structure(non-packing type). Based on the proven technology in stationary pilot test facility as well as in actual real ship tests, we have ensured optimal desulfurization efficiency and verified the problems that can occur in the ship with our proven solutions.

Flexible Design for Any Installation

Specification Hyundai Materials EGCS
EGCS Operation Mode Open / Closed / Hybrid
Scrubber Type U-Type / I-Type(In-Line)
Engine Rated Power Up to 40MW
SOx Removal Efficiency 99% (IMO requirements satisfied)
Pressure Drop of Scrubber Meets Engine Requirement
Applications New Building / Retrofit

Benefits of Hyundai Materials EGCS

Compact

The slim design of our marine scrubber makes it the right choice for a retrofit. The reduced volume of our scrubber will allow to fit in the vessel without additional layout changes

Compact
Non Packing Type

Our scrubber system does not include venturi and pack beds, instead of pack beds, we applied distributors and variable nozzles to achieve low back pressure, cost efficiency and easy maintenance.

Non Packing Type
Proven Technology

Hyundai Materials has optimized the scrubber performance through case studies on stationary pilot test bed and installed it on a marine engine (7MW) to ensure reliability and stability through demonstration.

  • SOx Pilot test bed

    SOx Pilot test bed

  • Engine Demonstration

    Engine Demonstration

System Diagram

Hyundai Materials Exhaust Gas Cleaning System, which removes sulfur oxides for the marine environment, is mainly classified into Open Mode, Close Mode, and Hybrid Mode. In Open Mode, Sea water is used as Wash water, in Close Mode, Alkali solution is used as Wash water and in Hybrid Mode, mode switch between Open Mode and Close Mode is available.

Non Packing Type
  • Open Loop EGCS

    In Open Mode, Sea water is used as Wash water. Natural features of sea water removing sulfur dioxide are the main mechanism of Exhaust Gas Cleaning Process. In Open Mode System, Sea water is provided by Sea Water Supply Pump.

    Operation for sea going(normal operation)
  • Closed Loop EGCS

    Close mode system circulates wash water in wash water tank. Wash water is supplied to the scrubber by the wash water pump through the cooler. The used wash water coming out from the scrubber is collected back into the wash water tank and reused.

    Operation low alkali zones & zero discharge zones

Scrubber Type

Scrubber is divided into I-Type and U-Type. Depending on the configuration of main engine, aux. engine and boiler etc., I-Type is classified into single stream system and combined stream system and U–Type is composed of single inlet and multi inlet System. Considering installation spaces and bypass system requirements, we provide 2 types of scrubbers for each condition.

  • U Type Scrubber

    U Type Scrubber

    Suitable for multi inlet (integrated) scrubber
    Bypass duct required
    Favorable for building new vessels

    Engine Power A B
    MW Mm mm
    6 2,100 6,600
    12 2,900 7,100
    22 3,800 8,050
    30 4,900 8,850
    40 6,000 9,250
  • In Line Scrubber

    In Line Scrubber

    Suitable for single inlet without bypass
    Dry operation is possible
    Favorable for retrofit due to small footprint

    Engine Power A B
    MW Mm mm
    6 1,900 7,169
    12 2,700 8,487
    22 3,600 9,983
    30 4,600 11,706
    40 5,600 12,830

SCR System Overview

SCR System Overview
SCR is an after-treatment technology that selectively reduces nitrogen oxides (NOx) from the emission.
NOx is converted to nitrogen (N2) and water vapor (H2O) which is harmless to human body by a reducing agent and catalyst. Ammonia or urea is mainly used as the reducing agent. Since January 1, 2016, the International Maritime Organization (IMO) has entered into an agreement 'Tier III' to reduce the emission of nitrogen oxides from diesel engines by more than 80%, and SCR must be installed to marine engines to comply with the Tier III standard. Hyundai Materials is able to manufacture and supply all SCR products from small engines to large engines, and provides solutions that meet customers' requirements and environmental regulations.

HM SCR System Features

  • Hybrid design (bypass combined)
  • Optimized control logic (PLC)
  • Convenient installation
  • Easy maintenance & exchange
  • Compact volume (catalyst tech.)
  • Reduced volume and weight

SCR System Key Technologies

  • HM SCR System Features
  • Dosing
    System
    • Cost-cutting precise urea injection
    • Stability through optimized programed logic
    • Compatible with various types of engines
    Chamber
    • Convenient assembly and exchange of catalyst
    • Bypass line combined design
    • Volume and weight reduction
    Mixing
    • Improvement of urea decomposition capability
    • Compact system by static mixer design

SCR System Components

SCR Chamber
SCR Chamber
It consists of De-NOx catalysts and housing including thermocouples and differential pressure transmitter to send the signals fo gas temperature and differential pressure throughout the catalyst.
USU (Urea Supply Unit)
USU (Urea Supply Unit)
USU has two pumps including a standby pump. It supplies urea 40% solution from the urea tank to UDU. It has a local panel to shut down at local area for emergency and maintenance.
UDU (Urea Dosing Unit)
UDU (Urea Dosing Unit)
UDU consists of control valve and flowmeter, some instruments / valves and it is a PID control type and communicates with control panel. It serves a high accurate / dynamic response to variation of engine loads.
Control Panel
Control Panel
It is operating based on input signal from the engine controller and signal communicate with other devices(SCR chamber, UDU, USU). Control panel ensures accurate response for NOx reduction.
Compact SCRfor High Speed Marine Engines

Hyundai Materials offers an solution which is an engine-integrated Compact SCR system. Usually, the SCR chamber is very large and contains a lot of separate components, so it requires a lot of space. For this matter, Hyundai Materials offers an solution which is an engine-integrated SCR system.
Compact SCR is optimized for small, high-speed engines. Due to a single type metal catalyst instead of the conventional honeycomb catalyst, the size is compact and the system is simplified. In addition, high-speed engines require high catalytic performance at high temperatures due to their high gas temperatures. Hyundai Materials has developed and applied high-temperature-only catalysts to achieve a reduction efficiency of over 90%.

Compact SCR
Application
high speed marine engines up to 600kw power (small vessels, locomotive etc.)
Benefits

Compact Built-In Size by Metal Substrate Catalyst

Optimized performance for high temp

Simplified System by dosing pump

Easy Maintenance by single piece catalyst

The commercial decision

The commercial decision
Engine Power Standards
160 ~ 200kw HMCS-A
200 ~ 410kw HMCS-B
410 ~ 500kw HMCS-C
500 ~ 600kw HMCS-D
Metal Substrate Catalyst Excellent choice for stronger and more durable catalyst in all applications

Hyundai Materials has developed a new type of metal catalyst that overcomes the weakness of the conventional ceramic extruded catalysts. The catalyst materials is coated on a stainless steel structure, and because of its thin wall thickness, unit cell has very high porosity. Even if it has the same volume as ceramic catalyst, its surface area is high compared to honeycomb structure, which makes possible to build a compact system. In addition, since the structure is made of metal, it has excellent durability and does not break easy as the honeycomb catalyst does, and it is very advantageous in back pressure because of its high porosity.

Non Packing Type
Comparison with Honeycomb(conventional type)
Conventional Honeycomb Calayst Metal Structure Calayst Variable Shapes
Non Packing Type
  • General Surface Area
  • Easily Domaged
  • Lower Thermal Conductivity
  • General Life time
  • No Recycling
Non Packing Type
  • Increased Surface Area
  • Higher Strength
  • Higher Conducrivity
  • Longer Life time
  • Catalyst Recycling
Non Packing Type

* By client demand, we can also provide Ceramic catalyst.

Metal Substrate Catalyst

Metal substrate catalyst is superior to ceramic catalyst in terms of increased specific surface area, porosity, strength, and stability against heat.

Specification Honeycomb Catalyst HM Metal Catalyst Metal Catalyst Benefits
Wall Thickness  0.3 ~ 1.45mm  0.03 ~ 0.1mm  Reduction of cell clogging
Density  Cell/in2  5 ~100  13 ~100 
Cell/150x150  13 ~ 60  21 ~ 60 
Strength  5~20kgf/cm2 80 ~ 130kgf/cm2 Prevention of damage
Porosity  73 ~77%  76 ~91%  Lower back pressure
Surface Area 300 ~ 1,400m2/m3  630 ~ 1,520m2/m3  Enhanced De-NOx performance
Thermal Conductivity  1.0w/mㆍk  23.3w/mㆍk  Faster reaction & cold start
Space Velocity  7,000 ~
12,000h-1 
16,000 ~
20,000h-1 
Decreased weight and volume
Element Structure  Full body extrusion

Full body extrusion

Full body extrusion

Metallic structure

Metal structure recycling available
Specification HMC - 13 HMC - 20 HMC - 30 HMC - 40 HMC - 50 HMC - 70 HMC - 100
Cell Density[cpsi]1) 13 20 30 40 50 70 100
Number of Cell 20 26 32 37 42 49 59
Wall Thickness[mm] 0.1 ~ 0.03
Surface Area[m2/m3] 583 714 862 986 1,095 1,284 1,520
Void Fraction[%] 80.2 79.7 79.1 78.6 78.1 77.3 76.2
Application COAL OIL GAS

S-DPF (SCR on DPF)for both NOx & PM

When particulate matter and nitrogen oxides are simultaneously reduced in the exhaust gas, it is common to separately install a DPF to reduce PM and SCR catalyst to reduce nitrogen oxides (NOx).

In this case, a large amount of installation space is required. To solve this problem, Hyundai Material has developed sDRF (SCR on DPF), a hybrid type integrated filter catalyst, which the SCR catalyst is coated on DPF filter. The volume is reduced by more than 35%, and the reductant injection device for SCR reaction is also applied inside the chamber, which simplifies the system configuration.

S-DPF (SCR on DPF)
  • Active Regeneration

    Suitable for All types of Fuels(incl. HFO)

    Active Regeneration
  • Passive Regeneration

    Suitable for Low Sulfur Fuels

    Passive Regeneration
Oxidation System

Hydrocarbons, carbon monoxide, and methane can be reduced through oxidation catalysts (DOC) that contain precious metals. In addition, to reduce soot, the NO in the exhaust gas is oxidized to NO2 to remove carbon trapped in the filter. In addition, when the NO2 content is increased, the SCR reaction rate is increased since NO2 causes fast SCR reaction as a result the De-NOx performance is enhanced by the DOC. Moreover for Methane (CH4), which is known as a representative greenhouse gas, is generated in the case of an engine using natural gas as a fuel.(Gas engines & Dual fuel engines) The Oxidation catalysts also functions to reduce methane.

Carbon Oxidation(CO) THC(Total Hydro Carbon) Methane(CH4)
Carbon monoxide is a gas formed in an unstable state of carbon and oxygen and it is classified to a harmful gas because it reacts with hemoglobin and causes an addiction to the human body. When the heat and oxygen needed for the reaction are supplied, it becomes an harmless and stable molecule called carbon dioxide through the oxidation catalyst. Hydrocarbons are emitted as unburned hydrocarbons from fuels, or by generated during the chemical reaction from combustion. When reacting with oxygen and nitrogen compounds, it becomes aldehyde which is a toxic substance to human and becomes a source of photochemical smog. Methane is classified as a greenhouse gas because it has a long remaining time and absorbs infrared rays, and the amount emitted from carbon dioxide is very small, but the Global Warming Potential of methane is 21 times that of carbon dioxide per unit volume. Methane is closely related to the fuel composition and is produced in the engine by incomplete combustion, and in particular, a large amount of LNG gas is released as a slip.

Platinum Group Metal (Pt, Pd)

Platinum Group Metal (Pt, Pd)
Other Functions
  • Ammonia(NH3) slip reduction
  • Gas engine methane slip reduction
  • Urea hydrolysis catalyst

REFERENCES

Application Items Ship yard / Site
Marine
Application 
• Plant Supply Vessel(SCR System, 8unit/2 vessel)  Cheongdo ship yard, China 
• Crude Oil Tanker(SCR System, 6unit/2 vessel)  Hyundai Samho 
• Commercial Vessel(SCR System, 8unit/2 vessel)  Hanjin Heavy Industry 
• Crude Oil Tanker(SCR System, 6unit/2 vessel)  DSME 
• Crude Oil Tanker (SCR System, 6unit/2 vessel)  Hyundai Samho 
• Crude Oil Tanker(SCR System, 3unit/1 vessel) Hyundai Samho 
• Container Ship(SCR System,12unit/4 vessel) Hyundai Heavy Industries 
• Crude Oil Tanker (SCR System, 12unit/4 vessel) Hyundai Samho 
• Container Ship(SCR System, 6unit/2 vessel) Hyundai Heavy Industries 
• Crude Oil Tanker (SCR System, 9 unit/3vessel)  DSME 
• DW, SH, S Project order intake (51EA)  HHI, DSME, Samhom etc. 
Stationary
Application
• Coal fired Power Plant De-NOx Catalyst(100m3)  Daegu Dyeing Power Plant 
• Engine Power Plant DOC / DPF / SCR System  Korea Wido Island 
• Regenerated Fuel Engine Power Plant(DOC/DPF)  Korea Yunchun Power Plant 
• Natural Gas Power Plant(Oxidation System) Indonesia 70MW GPP 

Marine SCR Retrofit

SCR products were supplied and installed in the Mokpo Maritime University training ship in the second half of 2014 and are operating steadily until now. Due to the compact size of Hyundai Materials system, retrofit process was carried out with no problems in installation.

Marine SCR Retrofit

Engine Power Plant All-in-One System

We provided DPF and SCR system for PM1) & NOx emission reduction for island areas which is operated by diesel generator engines. Additional projects for remote island power stations is ongoing.

Engine Power Plant All-in-One System

Power Plant SCR Catalyst (Metal Substrate Catalyst)

We manufactured and installed Metal Substrate Catalyst to DAEGU dyeing cogeneration Power Plant for high dust De-NOx solution.

Power Plant SCR Catalyst  (Metal Substrate Catalyst)

Engine Power Plant

We are not only supplying globally to engine power plants that use diesel fuels, but also to engine power plants that use regenerated oils or natural gas fuels. And also CO reduction facility for Dual Fuel Engine in Indonesia is also installed in 2018.

Engine Power Plant
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