Marine Essentials - Alfa Laval

Waste fuel recoveryAdaptive fuel treatmentWaste oil is a problem from multiple perspectives. It contains a significant amount of liquid,which means large volumes to be landed orpumped onto barges. Moreover, much of thatliquid is fuel.Alfa Laval led the way in adaptive oil treatment with Alcap, which lets the Alfa Laval Sseparator adjust automatically to oil composition. Today, the Alfa Laval adaptive fuel lineoffers even more efficient engine protection.Alfa Laval PureDry is the only solution that canremove every drop of liquid from waste oil,leaving only super-dry solids. If separate tanksare used for fuel and lube waste, this revolutionary separator can even recover reusablefuel – as much as 1-2% of yourvessel’s fuel consumption.Synchronization with the engine load is a keyaspect. Alfa Laval FlowSync reduces energyconsumption by steplessly adjusting theseparator feed. This also gives the oil moretime in the separator bowl, which enhancesthe S separator’s already leadingcat fine removal.Read more on p. 59Read more on p. 42, 48Contribution to EEDIWorking with new fuelsFor new vessels, the Energy Efficiency DesignIndex (EEDI) is an important parameter. Whilethe choice of engine and hull design are keyto achieving EEDI targets, waste heat recoverywith Alfa Laval Aalborg systems can contribute to a successful rating.Stricter emissions limits have led to a rapiddiversification of maritime fuels. TraditionalHFO, MGO and MDO are now joined by LNG,LPG, methanol, ethanol and DME.Waste heat recovery offers much more thansteam for direct use. It can be used to generate electricity, which can be diverted to amotor in the shaft line for use in propulsion.This has a positive influence on your EEDI rating.Read more on p. 79These new fuels pose new challenges, frompumping at extreme pressures to supplyingfuel at far lower temperatures. Drawingon full application knowledge and fuel conditioning experience no other supplier canmatch, Alfa Laval is meeting these challengeswith solutions like theAlfa Laval FCM One Gas andLow-Flashpoint Fuel (LFF).Read more on p. 50

12

B A L L A S T WAT E R T R E AT M E N TBallast water treatment is no longer tomorrow’s issue.With global requirements now in place, more customers thanever are negotiating and installing their ballast water treatmentsystems. The questions today are not only about compliance,but also about operating and business flexibility.Ballast watertreatmentCompliance with all the possibilitiesAlfa Laval has worked with ballast water treatment formore than a decade. As the very first commerciallyavailable ballast water treatment system, Alfa LavalPureBallast defined the forefront at the time of itslaunch – and still does today.PureBallast 3.1 represents a complete range ofsolutions for both newbuild and retrofit needs,including the needs of smaller vessels. Providinga capability range unequalled by any other system,it allows vessels to comply with IMO and U.S. CoastGuard regulations without restricting their businesspotential.Performance without compromisePureBallast 3.1 offers unmatched biologicaldisinfection performance in any type of water: fresh,brackish or marine. This includes water in liquid format frigid temperatures, as well as low-clarity water.When operating in IMO-regulated waters, the systemperforms at full flow where the UV transmittance isas low as 42%.For vessels with PureBallast 3.1 installed, this meansreliable compliance with maximum freedom of move ment. Added to it are the expert resources of AlfaLaval’s worldwide organization, along with a welldeveloped service offering for total peace of mind. 13

B A L L A S T WAT E R T R E AT M E N TBallast water treatmentPureBallast 3.1Alfa Laval PureBallast 3.1 is an automated inlinesystem for the biological disinfection of ballast water.Operating without chemicals in all water types, itcombines initial filtration with an enhanced form ofUV treatment to remove organisms in accordance withstipulated limits. Disinfection occurs in an enhancedUV reactor, whose specially designed synthetic quartzlamp sleeves support transmission of a broaderwavelength spectrum. Combined with the reactor’sinternal design, this ensures optimal UV dosage andunmatched biological disinfection performance. Whenoperating in IMO-regulated waters, full-flow treatment ispossible where the UV transmittance is as low as 42%. IMOand U.S. Coast Guard (USCG) type approvalsperformance in all water typesfresh, brackish and marine Excellent performance in low-clarity waters Treatment of water in liquid form atfrigid temperatures Fully automated, chemical-free operation Superior Effectivepower management (typical operationat 50% power in IMO-regulated waters) Flexible installation based on compact modularcomponents Flows of 32–3000 m3/h with a standard system andlarger flows with multiple systems Complete newbuild and retrofit solutions, includingownership support and Performance Agreements Upgrade option from IMO to U.S. Coast Guard typeapprovalEquipment:filter Reactor Lamp drive cabinet Cleaning-in-Place (CIP) unit Control cabinet Auxiliary equipment BasketAlfa Laval PureBallast 3.1 (600 m3/h)14

B A L L A S T WAT E R T R E AT M E N TPureBallast 3.1 ExAlfa Laval PureBallast 3.1 is available in Exconfigurations according to ATEX and IECEx, Zone 1,IIC and T4. Ex designs are simplified by the flexibleplacement of the lamp drive cabinets, which can belocated outside the hazardous zone and up to 150 maway from the reactors they serve. Redundant safetyfeatures, such as the connection of the reactortemperature and level sensors via relays that bypassthe PLC, increase safety in operation.Easy upgrade to USCG type approvalPureBallast 3.1 is available both as USCG Typeapproved system for use in US waters or solely as IMOapproved system for use only in IMO-regulated waters.Installing a USCG TA system provides flexibility ofdeballasting in United States waters as well as IMOregulated waters. It also protects the vessel’s resalevalue, since a vessel that does not have the potential forUSCG type approval will be difficult to sell to any buyerwho wants to operate in this key market.PureBallast 3.1 Compact familyThe family of Alfa Laval PureBallast 3.1 Compactsystems is ideal where space on board is cramped.PureBallast 3.1 Compact systems use the sameenhanced UV technology and offer the same biologicaldisinfection performance as other PureBallast 3.1systems. But they are configured specifically for a smallfootprint and can be delivered either as loosecomponents or on a skid. Skid-mounted systems arecomplete with prefabricated pipework and pre-testedfor plug-and-play installation. Flowsof 32–1000 m3/h Delivery as loose components or on skid Small footprint Integration of lamp and control cabinets intoa single electrical cabinet Connection via simple plug-and-play contactsAlfa Laval PureBallast 3.1 Compact (170 m3/h)Tailored retrofits and supportThe compactness and flexibility of PureBallast 3.1 areadvantageous for existing vessels where ballast watertreatment was not considered in the original design. Inaddition, Alfa Laval has knowledge and proven workingprocedures that simplify a retrofit. We can work withyour engineering department and chosen yard, orsecure competencies from our own network forengineering support, class approval and more.With our worldwide presence, Alfa Laval can meet yourdocking schedule or arrange for retrofit during yourvoyage – and move with your project if plans change. Thesame global organization then provides lifetime supportwith a well-developed service offering (more on page 87). 15

CARGO HANDLINGFramo hydraulically driven submerged cargo pumps providesafe, efficient and flexible cargo handling of any type of liquidcargo. Improved cargo handling performance gives quickerturnaround time, more ton-miles and fewer voyages in ballast.Sold and serviced byFramo AS onlyCargo handlingMade to performFramo cargo pumps are of a robust construction madeto efficiently empty any cargo tank containing the mostheavy, viscous or aggressive cargoes.The hydraulic driveline is designed for safe and reliablepumping and final stripping of the most volatile ordangerous cargoes carried in bulk.There is no risk of any build up of heat, due to afail-safe design where the pump motor and bearingsare constantly lubricated and cooled.Load any type of cargoFramo cargo pumps can handle any type of cargo. Onevoyage it may be a petroleum product, the next voyagean acid or something heated, cooled, volatileor viscous.Framo cargo pumps also allow efficient switchingbetween different cargoes. A cargo pumping systemmust be able to discharge, drain and clean the cargotanks in an efficient manner to make the vessel readyto receive a new cargo. 17

C O O L I N G A N D H E AT I N GOil and water heating and coolingCBMVirtually maintenance-free, the Alfa Laval CBM plateheat exchanger has a compact and cost-effectivedesign that is easy to install or retrofit, even in confinedspaces. It comprises corrugated steel plates heldtogether with copper brazing, which ensures optimalheat transfer efficiency and pressure resistance. TheCBM covers a large range of applications and can betailor-made for a particular duty, with various connectionstandards and connection sizes of 30–100 mm.In addition, there is a preconfigured solution known asthe HEATPAC CBM, specially designed for the heatingof mineral oil prior to separation. The HEATPAC CBM,which is available with two connection sizes and with20, 40, 60, 80 or 100 plates, is able to handle dutiesup to 30 m3/h.Compatible media: Waterinvestment Optimum use of space Minimal maintenance – no replacement parts400 or 700 mm Oil Low-cost Steam Thermaloilsolution Most refrigerants GlycolAlfa Laval CBM400FiltrationAlfa LavalHEATPAC CBMAutomatic self-cleaning filter, ALFPort filterSimple and cost-effective to install, the automaticself-cleaning filter protects a plate heat exchangerby removing debris at the seawater intake. Installedbetween the seawater pumps and the PHE itself,it provides continuous filtration of the cooling water.Collected debris is automatically removed withoutdisrupting the liquid flow. The filter is easy to service,since the filter basket can be removed withoutremoving the pipes.The port filter is a low-cost alternative to the Alfa LavalALF filter. Installed in the seawater inlet port of a plateheat exchanger, it prevents the PHE from clogging withdebris that may have passed through the mainseawater intake filters/strainers. Removal of the portfilter for maintenance is performed from the pressureplate side of the PHE, which means that dismantling ofthe inlet pipework is avoided. Materials: Preventionof PHE cloggingautomatic cleaning process Short flushing period with flexible regulation offlushing intervals Low pressure drop Easy service without removing pipes Electrical, pneumatic or hydraulic actuators Continuous,Alloy 254(for seawater), titanium, Alloy316L Standard mesh size:Ø 1.5–2.2 mm Δcorresponding to opensurface of 37%Alfa Laval port filterAvailable in two models: ALF-S (stainless steel) ALF-R (rubber-linedcarbon steel)Alfa Laval ALF 29

C O O L I N G A N D H E AT I N GCleaning-in-PlaceCleaning-in-Place (CIP) systemsfor heat exchangers1550 mmAlfa Laval Cleaning-in-Place (CIP) systems are a simpleway to keep heat exchangers of all types performingoptimally. Connected directly to the heat exchangerports, they circulate heated, usually biodegradablefluids that effectively dissolve scale, sludge andmicroorganisms. In this way, the fouling that reducesheat transfer can easily be removed without any needto dismantle the heat exchanger. Not only does thissave time on cleaning, it helps to prolong plate andgasket lifetimes. Easyoperationgasket life – no damage Heating of cleaning fluids withelectricity or steam Compatibility with spiral, shelland-tube, gasketed, welded andbrazed heat exchangers A range of models and sizes available ProlongedAlfa LavalAlfa-CIP 200LCleaning-in-Place (CIP) fluidfor heat exchangersAlfa Laval Cleaning-in-Place (CIP) fluids for heatexchangers are designed to keep your equipment inpeak condition without endangering fragile marineecosystems. All of the fluids are non-hazardous, andmany of them are also biodegradable. Most gentle isthe general-use line of Alpacon fluids, which containa unique raw material based on fermented whey.Fluids for general use:Descalant Alpacon Degreaser AlpaconFluids specific to heat exchangers: AlfaPhos AlfaCaus AlfaNeutra AlfaAddSafe and natural ingredientsAlfa Laval’s high-performance fluids for Cleaning-inPlace (CIP) systems are non-hazardous, which meansthat no health risks are posed and no protectiveequipment is necessary. They are also safe for theenvironment, as they are based to the greatest possibleextent on gentle, natural ingredients.30

D E S A L I N AT I O NWater is the most abundant substance at sea, but the saltand impurities seawater contains make it unsuitable for mostpurposes on board. Alfa Laval’s freshwater generators let youtake economical advantage of this resource and do awaywith expensive, low-quality bunker water.DesalinationSmarter ways to fresh waterAlfa Laval pioneered the compact and cost-efficientproduction of fresh water. Over 50 years ago, weintroduced thermally driven freshwater generators withdual-plate-pack technology. These were not onlysmaller than shell-and-tube installations, but also farless sensitive to scaling.Reducing energy use and emissionsA major advantage of the three-in-one AQUAplate technology is the fact that it cuts seawaterrequirements in half. This allows smaller pipes andpumps to be used, which means a reduced initialinvestment, easier installation and lower energyconsumption – with lower CO2 emissions as a result.Today we’ve further developed our plate concept,enabling vacuum distillation within a single plate pack.Our Alfa Laval AQUA Blue freshwater generator, whichhouses the vacuum in the plate pack itself, containsrevolutionary three-in-one titanium plates on whichevaporation, separation and condensation all occur.But the energy efficiency is not limited to AQUA Blue.Where larger volumes of fresh water are needed, ourAlfa Laval multi-effect plate (MEP) desalination planttypically consumes just 1.3–3.0 kWh/m3, thanks to anoptimized pump configuration and a frequencycontrolled motor on the seawater pump. 31

D E S A L I N AT I O NSeawater desalinationAQUA BlueThe Alfa Laval AQUA Blue freshwater generatorutilizes Alfa Laval’s pioneering AQUA plate technology.As a result, it uses just half the pumping energy of otherfreshwater generators – because it requires only half asmuch seawater. Distillation occurs in a single platepack, assembled from a single type of purpose-builttitanium plate. In AQUA Blue, this technology iscombined with a wide range of enhancements foreasier installation and simpler operation. Minimalmaintenance is required, and the plate pack slidesopen for easy access to the interior without anadditional service area.Alfa Laval AQUA Blue 3-in-1plate technology (evaporation, separation,condensation) Half the seawater pumping needs of otherfreshwater generators Energy-efficient IE3 motor Intuitive operator interface Robustconstruction with duplex pipingcompact installation with less investment Optional high-pressure capabilities Max. salinity: 2 ppm Capacity: 2–60 m3/24 h Simple,Less fuel used for pumpingOptional high-pressure configurationBecause the AQUA Blue freshwater generator requiresonly half the seawater flow of other freshwater generators,pumping requirements are cut by 50%. This allowssmaller seawater pumps to be used, and it means thatthe pumps consume less electric power. Since energyon board ultimately comes from the burning of fuel, thismeans a positive affect on both fuel consumption andCO2 emissions.Jacket water often provides the heat for desalination,and today’s jacket water pressures are frequently higherthan 4 bar. There is thus a high-pressure option forAQUA Blue. This high-strength configuration performsaboard large vessels with deep draft and providesadditional installation flexibility for shipyards.Utility plateProcess plate5462761833211Seawater feed2Heating medium in3Heating medium outGreySeparation4Seawater cooling inRedEvaporation5Seawater cooling out6Evaporated vapour7Fresh water out8Brine outGreenCondensation

D E S A L I N AT I O N Lowproduction costand user-friendly control technology Fast start-up and quick response to load changes Titanium plates that resist seawater corrosion Patented plate design and falling film process forhigh thermal efficiency Unique construction that allows direct access toheating surfaces Evaporator vessel of AISI 316L steel High distillate purity and salinity of 5-10 ppm Capacity: 200–1000 m3/24 h per unit State-of-the-artDPU freshwater generatorsAlfa Laval DPU freshwater generators use vacuumdistillation to provide constant fresh water throughout aship’s lifetime. Designed for automatic two-stageoperation, they save energy by using vapour from thefirst stage as a heating medium for the second. Withtitanium plates in the heat exchangers and non-ferrousmaterials throughout, they have a low scaling rate andnon-corroding vital parts. Front-cover access makes iteasy to perform the little maintenance needed, and noadjustment is required after tuning to operatingcond

Alfa Laval led the way in adaptive oil treat-ment with Alcap, which lets the Alfa Laval S separator adjust automatically to oil composi-tion. Today, the Alfa Laval adaptive fuel line offers even more efficient engine protection. Synchronization with the e