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Driven by IT: Innovations in Port Operations

Terminal Operation optimized by Emulation and Simulation Technology

Prof. Dr.-Ing. Holger Schütt

October 27th2010

American Association of Port Authorities 703.684.5700 •www.aapa-ports.org

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Agenda

Institute of Shipping Economics and Logistics

Terminal planning and operation supported by simulation/emulation

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Institute of Shipping Economics

and Logistics

ISL Bremen, Universitaetsallee

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Short Profile

Legal Form

Independent, private non-profit foundation

Our Philosophy

Research based consultancy institute

Founded in

1954

Locations

Bremen, Bremerhaven

Capacity

60 permanent staff members

Directorate

Prof. Dr. Hans-Dietrich Haasis Prof. Dr. Manfred Zachcial Prof. Dr. Frank Arendt Prof. Dr. Burkhard Lemper

Board of Trustees

Decision makers from industry, science and politics

Scientific Advisory

Board

Experts from transport industry, commerce and science

Sponsoring Body

Companies and individual members from the maritime industry

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Two special competence centers are located in Bremerhaven:

Auto-ID and Security in Container Transport

Information Logistics

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Simulation* : SCUSY, CAPS und CRASY

Various operation systems, terminals of different sizes, strategies

worldwide Consulting

Sale of simulation tools

Device-Emulator ViTO

Test bed for TOS (Terminal Operating System)

Operations Research in logistics

Order distribution

Stowage planning

Pooling

COSMA

Container Management System for small sized terminals

incl. Automation

*

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Terminal planning and optimisation

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Experiences with emulation technology

2003

- concept of a SCUSY based emulation product - development of DeCoNet (comm. network) - Eurogate group 1st client (for all terminals) - client may use ViTO

-configuration of terminal layout -assignment of devices and jobs

- external emulators may be plugged to ViTO Warsteiner yard/crane emulator

Siemens crane emulator Update warehouse emulator DHL ZPMC horizontal transp. emulator

1989

development of SCUSY

- module based architecture - layout editor, input module

- simulation module - evaluation module

1991

head of division simulation at consultancy company within HHLA group

- emulation of high bay warehouse -simulation/emulation support of

automated CT Altenwerder/Germany (1999-2002, emulators still in use)

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Hinterland logistics

Goods flow simulation

TRIPS (Port call strategies)

Hinterland terminal

Simulation of logistic processes using standard tools

Offshore wind farms

Operations Research in logistics

E.g. warehousing

3D Visualisation

Animation toolbox

Specific tools

IYCAPS Simulation of intermodal Yards

ATIS

A

uto

T

erminal-

I

nformation and Management

S

ystem

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Optimisation and Simulation – References

APM Terminals

ASEAN Terminals, Philippines

Bejaia Mediterranean Terminal, Algeria Centerm Terminal, Vancouver, Canada Contship, La Spezia, Italy

CSX, Jacksonville, USA

DP World Terminal Antwerp, Europe DP World, Australia

EUROGATE, Bremerhaven, Germany EUROGATE, Hamburg, Germany HHLA, Hamburg , Germany

HPA Hamburg Port Authority, Germany HIT, Hong Kong

JadeWeserPort, Germany Kalmar Industries, Finland MCT, Gioia Tauro, Italy

MTL, Hong Kong

Nhava Sheva Terminal, India Noell Crane Systems, Germany NTB, Bremerhaven, Germany P&O Headquarter, London, Europe Port of Odessa, Ukraine

Port of Tacoma, USA

PORTEK International Ltd., Singapore Ports America, North America

Red Sea Gateway Terminal, Jeddah, UAE Sandwell Eng. Inc., Vancouver, Canada SCT, Southampton, U.K.

TRP, Buenos Aires, Argentina VTE, Genoa, Italy

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13 Container flow p.a. total

TEU MV FV 225.000 225.000 320.000 480.000 320.000 480.000 Gate Rail

Data analysis

2500000 TEU throughput p.a.

66,67% % share of 40' boxes

1500000 boxes throughput p.a.

8,00% % peak factor

2,00% % shortsea

modal split

import export import export import export

% % TEU TEU boxes boxes

total 50,00% 50,00% 1.250.000 1.250.000 750.000 750.000 shortsea 2,00% 2,00% 25.000 25.000 15.000 15.000 transhipment 18,00% 18,00% 225.000 225.000 135.000 135.000 landside 82,00% 82,00% 800.000 800.000 480.000 480.000 gate 60,00% 60,00% 480.000 480.000 288.000 288.000 rail 40,00% 40,00% 320.000 320.000 192.000 192.000 Standard parameter throughput p.a.

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Data analysis

container mix

transhipment gate railway

empties 3,45% 45,00% 45,00% reefer 8,00% 5,00% 5,00% oversize 0,00% 0,00% 0,00% hazardous 0,00% 0,00% 0,00% standard 88,55% 50,00% 50,00% import dwell time

transhipment gate railway

standard 7,00 9,00 9,00 empties 9,00 8,00 8,00 reefers 7,00 9,00 9,00 oversize 7,00 9,00 9,00 hazardous 7,00 9,00 9,00 import

average utilization [TEU in terminal]

MTY TEU in standard blocks TEU

add. landside

import export import export import export movem. total

standard 3.820,99 3.821,07 5.917,81 5.866,75 3.945,21 3.911,17 0,00 27.283,00 27.283,00 empties 191,40 191,31 4.734,25 1.856,57 3.156,16 1.237,71 0,00 11.367,40 11.367,40 reefer 345,21 345,21 591,78 631,23 394,52 420,82 0,00 2.728,77 2.728,77 oversize 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 hazardous 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 incl. MTY/ standard

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Static view

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ISL Profil

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Terminal capacity

1,500 m quay length

24/7 operation

Average vessel length 330 m (incl. safety distance)

Average throughput per vessel 2,300 TEU

Average service time 24 h

Theoretical capacity

(1,500 / 330) * 365 *2,300 TEU ~ 3.8 MTEU pa ????

Static view is insufficient

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18 © ISL 2010

Where is the bottleneck

of the terminal?

(Quay or stacking area)

How much throughput

does a terminal cope with the existing

capacity?

Support and information concerning the questions

quay

utilisation

no. of cranes

required

no. of stacking slots

required

yard

utilisation

CAPS

Tool for determination of the maximum possible throughput

of a container terminal

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19 © ISL 2010

CAPS

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Capacity planning

What will be the

result if an other

vessel mix will

arrive?

What‘s the impact

of vessel‘s

accuracy?

Terminal capacity : 2,85 MTEU pa

...

What will be the

result if QC‘s

productivity

decreases from 30 to

27 mv/h?

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Reuse existing simulation models for

sensitivity analysis and for getting a better

understanding of the real terminal

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Simulation tools:: Terminal planning and

Optimisation

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25 © ISL 2010

planning

of new terminals

expansion

or reorganisation

of existing terminals

Support and information concerning the questions

best type

of equipment

no. of facilities

changes in layout

test of different strategies

for operation

SCUSY

Tool for decision making processes on the strategic and

design level

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Various layouts, which one is the best?

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29 © ISL 2010

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30 © ISL 2010

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Complex operation

simulation is

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Case study

Comparison of operation systems selected

equipment use

evaluation

production

centres

SC 1 over 3 RTG/TC No. of STSCs 12 12 12 No. of SCs 45 X X No. of TCs/AGVs X 53 56 No.of RTGs/RMGs X 25 17 STSC operation hours 1130 1074 1057 SC operation hours 5016 X X

TC/AGV operation hours X 5683 5300

RTG/RMG operation hours X 3141 2737

aver. service time external trucks 20 min 8 min 4 min

average service time 13.6 12 11.7

DS1000 aver. moves/hr (total) 147.0 167.0 171.0

aver. moves/hr per STSC 29.5 32.3 33.4

average service time 12.5 10.5 10.1

DS800 aver. moves/hr (total) 128.0 152.0 158.0

aver. moves/hr per STSC 29.3 31.5 32.9

average service time 4.5 4.3 4.1

F120 aver. moves/hr (total) 53.0 56.0 59.0

aver. moves/hr per STSC 21.3 21.6 22.83

average service time 8.8 8.0 7.8

F250 aver. moves/hr (total) 57.0 62.33 64.0

aver. moves/hr per STSC 20.4 21.5 22.6

total berth operation time 218.0 195.0 189.0

costs per move [€] 143.36 157.44 132.76

RMG/AGV auto

costs

The decision from an economical view is supported

based on operational costs and investment

... But what are

the ecological

impacts of the

terminal?

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Ecological impact

33

layout

simulation

state/time

- per device

- per sector

device type

definition

terminalsimulation

simulation

interface

climate

corrections

formulars

EPSIC

acoustic

calculations

EPSIC

output

device

noise parameter

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SCUSY-EPSIC

E

mbedding an acoustic evaluation in the

P

lanning programme

S

CUSY to improve noise control regarding

I

mmission and emission in planning and reorganisation of

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Use the results of simulation for economic

aspects as well as for ecologic aspects

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Straddle carrier 1o3

Handshakes during discharging, Straddle

1. QC

SC

handshake

with buffer

No further

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Handshakes during discharging, AGV

1. QC

AGV

direct handshake

no buffer

2. AGV

YG

direct handshake

no buffer

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Example horizontal transport

1. QC

trolley

direct handshake

no buffer

2. Trolley

v-crane

direct handshake

no buffer

3. v-crane - trolley

direct handshake

no buffer

4. trolley - YG

direct handshake

no buffer

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Direct handshake between devices requires

synchronisation between devices

the more direct handshakes are required

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Typical layout of automated terminals

Technical:

QC: >40 mv/h

Technical:

YG à 18 mv/h

Technical:

AGV à 12 mv/h

What may be

terminals

total

productivity ?

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Impacts to QC productivity

Technical P. (100%)

Real P. (50-80%)

Achievable

(80-90%)

stowage plan

Hatch cover m.

Potential for optimisation

Increase no. of transport

devices

Synchronise devices (TOS)

Decoupled handshake

Increase device utilisation

Short distance algorithms

Effective pre planning (yard

and eqiupment)

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Equipment and Control

Central control instead of decentral intelligence

Prevention of Collisions

Direct handshake requires synchronisation

Terminal Operating Systems are getting more and more complex

Within the first step the development of the IT for the fully automated Terminal

in Altenwerder had cost

26 M€

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47

Virtual T

erminal Optimisation Tool

47

What is ViTO?

more science based

universal

rtual

distributed

open

olbox

to plan, restructure or realize container terminals

Original ViTO screenshot

Vi

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Emulation definition:

A model that accepts the same inputs and produces

the same outputs as a given system

IEEE 610.3-1989

Emulation main concept:

Use the same TOS and switch between real or virtual terminal

Real Virtual

TOS

Terminal Operating System

switch

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Benefits vs. costs

Example for a study to optimise productivity

the study costs

some 80 T€

QC RTG TC FLT

No. 14 50 60 13

Op. Hours 5.500 3.500 4.500 4.000

Fixcosts p.a 8.925.000 € 7.625.000 € 4.104.000 € 478.400 €

Op. costs pa. 12.320.000 € 14.000.000 € 10.800.000 € 3.380.000 €

Personal costs 23.100.000 € 13.125.000 € 20.250.000 € 3.900.000 €

sum p.a. 44.345.000 € 34.750.000 € 35.154.000 € 7.758.400 €

total p.a. 122.007.400 €

operational cost (incl. personal) of the terminal (2.7 MTEU throughput) are

some100 M€ p.a.

1% increase in productivity leads to

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Virtual T

erminal Optimisation Tool

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Main fields of ViTO

what can you do with a virtual container terminal?

Original ViTO screenshot

Real-time 3D visualization of (planned and real) terminal operation

Planning and Reorganisation of container terminals via simulation

Development & testing of Terminal Operation Systems (TOS)

Validating the TOS functionality e.g. alternative strategies

On-the-job training of TOS

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Virtual T

erminal Optimisation Tool

ViTO main modules

what programs can be used

Project Manager

2D Terminal Editor

3D Terminal Viewer

Input Module

(base data)

Simulation Module

(SCUSY simulation)

Emulation Manager

(with more than 10 further emulators)

Evaluation Module

Utilities

Project Manager Terminal Editor 3D Terminal Viewer Simulation Emulation Manager Evaluation Module Input Module

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Virtual T

erminal Optimisation Tool

55

Supported terminal areas

what can you design with ViTO?

Original ViTO screenshot • Container stacks with single Containers

Internal and external traffic network with one-way roads

Gates

Truck interchanges

Rail tracks

Berth (Quay) areas

Parking areas

(import of own 3D models is possible (e.g. in 3ds format)

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Virtual T

erminal Optimisation Tool

Terminal devices in the standard package

what can be moved with ViTO?

Quay Cranes (movement and collision)

Straddle Carrier (collision control at handling areas)

Forklifts and Reach Stackers

External Trucks

Vessels (import of real Baplie files possible)

RMG and RTG *

Terminal-Chassis and AVGs (collision control at handling areas)

* under development

All in an unlimited quantity and with

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Virtual T

erminal Optimisation Tool

Individual features

what can additionally be done with ViTO?

Interface to TOS

Special logic of internal equipment handling (especially manned devices)

Import of terminal layout (direct import or comparison between TOS and ViTO)

Straddle Carrier, Terminal Chassis, AGVs: collision control in the traffic network

Import of external device emulators (also written in other languages, e.g. Java)

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Equipment

Emulator GateEmulator Quay

Emulator

Device Communication Network

online 3D realtime animation offline Yard Emulator online offline and more..

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29.10.2010 59

29.10.2010 59

Message exchange between clients =

XML

Straddle

Emulator Client 2 Client …

Emulation

Manager Logger

See also:

ViTO Interface Specification

Device Communication Network

Realtime 3D Animation

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Example SC-Terminal

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Example collision control

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Benefits using emulators

Original ViTO screenshot

Failures in the TOS are recognized before terminal implementation

Bottlenecks and design errors are discovered in an early phase

Analyzing and evaluation of alternative strategies

Check TOS updates without interrupting the operation

Checks may be realized in wear-free and energy-saving manner

Testing can be much faster (up to 100 times faster as in reality)

3D animation may be used for demonstration and training issues

Cost efficient solution over time

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Innovative

Solutions in maritime

Logistics.

Barkhausenstrasse 2 (t.i.m.e.Port II) 27568 Bremerhaven Germany Tel. +49/4 71/30 98 38-0 Fax +49/4 71/30 98 38-55 Universitaetsallee 11-13 28359 Bremen Germany Tel. +49/4 21/2 20 96-0 Fax +49/4 21/2 20 96-55

Institute of Shipping Economics and Logistics

schuett@isl.org

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66 www.isl.org info@isl.org

Insti

tut für S

ee

ver

kehrs

wi

rtsc

haft

und

Log

isti

k

Insti

tute

of

Shi

p

p

ing Economi

cs

and

Log

isti

cs

© ISL 2010

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PorTS

PorTS

Eco - PorTS

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Pilot Study, PorTS -Emission, (C) ISL 2008

Forecast Shipping Traffic

13.886 14.800 28.686 13.544 13.046 26.590 26.5 90 9.33 9 4.293 5.046 9.339 28.686

Schiffsverkehr auf der Unterelbe im Jahr 2015 (2004) (Anzahl Schiffe) (11.366) (12.366) (23.702) (6.301) (23.603) (2.735) (3.566) (12.147) (11.456) (23.702) (6.301) (23.603) 13.886 14.800 28.686 13.544 13.046 26.590 26.5 90 9.33 9 4.293 5.046 9.339 28.686

Schiffsverkehr auf der Unterelbe im Jahr 2015 (2004) (Anzahl Schiffe) (11.366) (12.366) (23.702) (6.301) (23.603) 13.886 14.800 28.686 13.544 13.046 26.590 26.5 90 9.33 9 4.293 5.046 9.339 28.686

Schiffsverkehr auf der Unterelbe im Jahr 2015 (2004) (Anzahl Schiffe) (11.366) (12.366) (23.702) (6.301) (23.603) (2.735) (3.566) (12.147) (11.456) (23.702) (6.301) (23.603)

Shipping Traffic on the Lower Elbe in 2015 (2004) (Number of Ships) Kiel-Canal Hamburg

Sea

Forecast of Throughput Development

for Port of Hamburg for several Years

- Container - Liquid Bulk - Dry Bulk - General Cargo - Cruise/Passenger Forecast of Fleet Development - Handling percentage

- Number of units to be handled - Multiple port calls

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68 www.isl.org info@isl.org

Insti

tut für S

ee

ver

kehrs

wi

rtsc

haft

und

Log

isti

k

Insti

tute

of

Shi

p

p

ing Economi

cs

and

Log

isti

cs

© ISL 2010 Quelle: HPA 111-5, 071017 Datei : Fol2286-a.ppt Fol.Nr. : 2286-a

Port of Hamburg - Future Investments

Port Infrastructure Planning, PorTS -Emission, (C) ISL 2008 Bf Hamburg Süd Veddel Altstadt Wilhelmsburg 1 255 Kleiner Finkenwerder Harburg E L B E Hafenerweiterungsgebiet Zone II

Border of ther Portarea Border between actual Port Area and Port Expansion

Port Rai (Hafenbahn)l Rail (Deutschen Bahn AG) Expressway/ Road 0 1 2 3 km Francop Waltershof Alte Süderelbe Logistikarea Southwest-Indiahafen Areal Central Freeport Container Terminal / Freight Village Altenwerder Logisticarea Dradenau Altenwerder Steinwerder Container Terminal Tollerort Container Terminal Burchardkai Grasbrook 7 Port of Hamburg Future Investments Restructuring (Finished) proposed present

Network Expansion (planned)

Rail Expansion „Hafenbahn“ Dredging 14,5 m Expansionplanning Logistic-Area Altenwerder West HABIS

„South Rail“ Connection CTA

Moorburg

Hafenerweiterungsgebiet Zone I

Option for Port Expansions Moorburg Rail link Scandinavia / Baltic (TEN) Restructure Finkenwerder Traffic Junction A 252 Container Terminal Eurogate

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Port Infrastructure Planning, PorTS -Emission, (C) ISL 2008

69

Source : HPA 12 Fol.No.: 2444

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Port Traffic Simulation, PorTS -Emission, (C) ISL 2008

70

Simulation/Animation

Tide dependent vessel from/to Hamburg

Tide independent vessel from/to Hamburg

Sea to Kiel Canal or

Kiel Canal to Sea

Sea to Elbe ports or

Elbe ports to sea

Ship-Traffic:

- Direct (Sea/ Kiel Canal, Kiel Canal/ Sea) - Origin/ Elbe ports/ Destination

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Port Traffic Simulation, PorTS -Emission, (C) ISL 2008

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Simulation/Animation: Port of Hamburg

(Zoom)

occupied turning circle segment-blocking waiting vessel turning circle

waterway

handling area

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Carbon Dioxide (CO

2

)

Sulphure Oxides

(

SO

X

)

Nitrogene Oxides (NO

X

)

Particulate Matter (PM)

Main Air-Emission in Maritime Transport

Pictures http://www.marinetalk.com/articles-marine-companies/art/Reducing-Air-Pollution-from-Ships-IMO00133728IN.html http://www.sustainableshipping.com/image/d/1106/25000.jpg; http://static.flickr.com/56/178991726_6d1c4905f3.jpg

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Air-Emission, PorTS -Emission, (C) ISL 2008

73

Greenhouse Gas Emission from Ships

Source: IMO, Prevention of Air Pollution from Ships – Report on the outcome of the IMO Study on Greenhouse Gas Emissions from Ships, MEPC 45/8, (2000), London, (Figure 3-9)

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Main factors of influence (Air-Emission)

VESSEL

Time per Segment Status

(Sea, Maneuver, Hotel)

REDUCTION

(per Em.Group) % Share of Fleet

% Share of Reduction AMP/Shore Side Electricity Berth-Time

„ENGINE LOAD“

Real Speed Per Segment

FUEL

HFO / MDO / MGO Sulfure Content

MAIN ENGINE

Installed KW Service speed RPM SFOC; FUEL-Type

AUXILIARIES

Installed KW % of Power (Status) SFOC; FUEL-Type

SO

x

NO

x

CO

2

PM

AIR-EMISSION

RPM Rotations per minute

SFOC Specific fuel oil consumption

HFO Heavy fuel oil MDO Marine diesel oil MGO Marine gas oil AMP Alternative maritime power

BOILER

% of Main Engine Power By Status SFOC; FUEL-Type

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World wide marine engines details

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PorTS -Emission, (C) ISL 2008

29.10.2010

77

Influence an Emission

Reduction

(Examples)

Modern Engines

After Treatments

AMP

Fuel

-Destilates

-Sulphur content

Pictures: Tiggers, Kay (Siemens AG Hamburg), Fuel Savings on Propulsion by Recovery of Thermal Energy – the Most Efficient Opportunity to Protect the Enviroment

http://www.sjofartsdir.no/upload/18198/Viking%20Line%20Solstrand%20060307.pdf www.sam-electronics.de; www.gauss.org;

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29.10.2010

Animation of Air Emissions

Emission SOx

Intervall Per Year

< 100 Tto

100-400 Tto

References

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