UREAGENERATOR INSTALLATION ON FSRU IN BRAZIL REDUCES COSTS AND EMISSIONS WHILST ADDING OPERATIONAL FLEXIBILITY

Framing the Challenge: Hoegh LNG engaged Fluechem to assess options to supply ISO standard AUS40 to one of their FSRU’s whilst on location in Santos, Brazil for an extended charter.

Identifying a Solution: Fluechem applied their specialist knowledge from the supply and delivery of AUS40 in Brazil and identified that to secure the required level of continuous, long term, emission control and compliance, the most appropriate solution would be to install a UreaGenerator on the FSRU and blend AUS40 from urea prills onboard.

UreaGenerator Key Benefits:

1. Weight Reduction: Eliminating the need to transport water reduces the weight of the product being delivered to the vessel by a substantial 60%. This translates into fewer trucks and barges, resulting in a 60% reduction in emissions and substantial logistics cost savings. In Brazil, where the vessel is positioned, there was no possibility of receiving trucks, and efficient supply was not available unless it met Ultra-Grade standards due to the strict supply conditions.
2. Enhanced Supply Chain Control: The UreaGenerator provides greater control over AUS40 availability, reducing supply risks and ensuring better compliance with regulations – urea prills being a widely available commodity;
3. Improved Quality Control: The system minimises shelf-life issues and lowers the risk of AUS40 contamination, resulting in better product quality control, which, considering the vessel’s complex supply setup, could have been catastrophic. Addressing this concern by attempting to remove off-spec AUS40 in Brazil would have been a colossal project, underscoring the system’s role in enhancing product quality control.
4. Streamlined Operations: The UreaGenerator system significantly reduces manpower requirements during loading and unloading operations and has no adverse impact on day-to-day shipboard operations and resources.
5. Increased Cargo Capacity: With reduced product weight onboard, the vessel can carry more cargo, leading to increased revenue;
6. Cost Savings: Beyond transportation and storage cost savings, the UreaGenerator delivers AUS40 directly onboard the vessel materially cheaper than local pre-blended product delivering overall cost savings.

The Collaborative Vessel Specific UreaGenerator System:

Fluechem, along with its technical partner ARAN, worked with Hoegh LNG on a vessel specific UreaGenerator system based on a number of key vessel requirements:

1. Capacity: Up to 1,500L/day. This capacity aligns with the vessel’s goal of maximizing their NOx emissions reduction efforts, as it’s sufficient to produce AUS40 up to ISO 18611 standards and subsequently convert it to AUS32.
2. Urea Handling: Capability to handle up to 1,000kg big bags of urea prills;
3. Installation: Modular installation with minimal vessel interfaces and construction risk;
4. Design: Semi-automatic loading system with low complexity and low technology risk;
5. Operation: Minimal O&M requirements interfaced into the vessel control system;
6. Utilities: Single point utility interfaces including the use of the vessel pot water system;
7. FAT: System fully assembled and tested at the factory prior to dispatch to the vessel;
8. Delivery: Available for delivery within four months form order receipt for installation onboard.

The Engineering and Construction Process:

During the initial phase, the agreed Functional Specification and basic design underwent a number of engineering reviews incorporating both technical and operational queries and clarifications raised by the FSRU project team and Fluechem engineering team. The agreed and documented clarifications were incorporated into the standard 1,500L/day UreaGenerator design to ensure the delivered system met the key requirements. The additional components including the semi-automatic urea big-bag discharging unit and hoist, grinder vale and hopper plus flexible screw conveyor were also incorporated into the UreaGenerator overall design and control system to ensure a single operational interface and minimum manpower requirements once installed.

Assembly and Testing:

Prior to dispatch from the factory all the elements of the UreaGenerator system were assembled and commissioned where after a full FAT was carried out to demonstrate the system capability to blend AUS40 to ISO standard. This allowed all interfaces and controls to be calibrated ready for installation and the operational manual to be updated to include operational commissioning by the ship’s crew once installed onboard.

The FAT was completed successfully and the equipment was tagged, dismantled and packaged ahead of schedule, ready for shipping directly to the vessel as it entered dock for conversion to a FSRU.

Installation and Commissioning:

The UreaGenerator system was delivered with a full set of operational spares and installed by the FSRU project team whereupon it was successfully commissioned post departure at sea by the vessel crew.

Operational Feedback

A proactive engagement with the vessel crew has allowed operational feedback to be incorporated into the basic design for future optimisation as part of a continuous improvement process. Operational performance has been in line with the requirements of the functional specification and met the vessel requirements whilst on location.

The innovative UreaGenerator by Fluechem is a cost-effective, market leading solution already installed and in use on vessels. It allows ship owners to blend their own urea solutions (AUS40 & DEF) onboard, providing security of supply with material cost savings while reducing environmental emissions even further.

“We are committed to reducing environmental emissions across all elements of our business,” said Niall Roberts, CEO of Fluechem. “The development and application of the UreaGenerator using the company’s know how and existing proven technology, allows us to offer material cost savings to our customers in a sustainable way within our overall environment goals. We look forward to these types of systems being the norm for vessels requiring AUS40 on a routine basis.”

“Höegh LNG commented: We are dedicated to sustainability and actively exploring new technologies to reduce emissions from our vessels. Our ongoing efforts reflect our commitment to a greener and more responsible maritime industry”, commented a representative from Höegh LNG.

If you would like more information or receive a vessel(s) specific proposal for the Fluechem UreaGenerator, speak to our team on +44 (0) 20 800 35 982 / +1 713 535 3930 or email info@fluechem.com We can design and install an UreaGenerator that will cover your ships IMO Tier III requirements; keeping you compliant whilst saving you money and reducing emissions even further.

Explore the Award-Winning UreaGenerator Presentation: Please take a moment to delve into our recent award-winning presentation, encapsulating the journey in all its glory.

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