Ballast water treatment energy-efficient and environmentally neutral

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1 GEA Westfalia Separator BallastMaster Ballast water treatment energy-efficient and environmentally neutral engineering for a better world GEA Mechanical Equipment

2 GEA Westfalia Separator seaprotectsolutions

3 Protection for the Maritime Environment and Your Investment GEA Westfalia Separator seaprotectsolutions Water is the source of all life on our planet it covers 70 percent of the earth. And international shipping lanes are now the primary arteries of the world economy. Over 90 percent of world trade is effected by freight transport using waterways by some 50,000 vessels. But the seas are also a highly sensitive ecosystem of crucial importance to humans and the environment. To protect this system in the long term, the International Maritime Organisation (IMO) and national legislators have issued strict directives and laws to cover the treatment of oils, slurries and bilgewater. Since 004, the control and management of ballast water has also become more of a focus. Even relatively mild cases of non-compliance lead to fines of tens of millions. In order to guarantee that a shipowner always has optimized operating costs and the most efficient on-board ballast water treatment performance for his ship, GEA Westfalia Separator Group supplies two versions of BallastMaster: the electrolysis-based ecop variant and the ultrav variant which uses UV-C radiation and ultrasonic. Both versions are perfect, both for building new ships and for retrofit application. For shipowners and operators, this means that ecological requirements and economic objectives have to be reliably combined in practice with their costs optimized. GEA Westfalia Separator Group developed a concept for this, called seaprotectsolutions, which comprises the latest systems for treating bilgewater, ballast water and sludge, as well as fuel. This wide-ranging portfolio involving cutting-edge technology made in Germany delivers customized solutions for long-term protection of both the maritime ecosystem and the value of shipowner investments. Efficient, future-proof ballast water treatment with GEA Westfalia Separator BallastMaster In the context of seaprotect solutions, the BallastMaster system performs the task of treating ballast water so that it can be pumped back into the sea containing no more than 10 living organisms of maximum size 40 microns per cubic metre in line with IMO guidelines. 3

4 GEA Westfalia Separator seaprotectsolutions High performance equipment to protect the marine ecosystems GEA Westfalia Separator Group offers leading techno logies and individual systems for marine use. Be it system engineering from one source, high quality of workmanship or the unrivalled worldwide service GEA Westfalia Separator Group provides a system to rely on. Product range overview Fuel oil treatment Fuel oil conditioning system Fuel oil conditioning system Lube oil treatment Sludge treatment Fuel oil service tank Bilgewater treatment Water desalination system Hydraulic oil treatment plants Ballast water treatment Fuel oil setting tank Fuel oil treatment Lube oil M.E. Fuel oil sludge tank Sludge treatment Lube oi A.E. Lube oil sludge tank 4

5 Water desalination system Bilgewater tank Bilgewater treatment l treatment Water tank Ballast water treatment il treatment 5

6 Billions of Pounds Worth of Damage from Stowaways Undesired spread of species from ballast water puts maritime ecosystem under threat Over ten billion tonnes of ballast water a year are transported all over the world by the international trade fleet. The problem is that when ballast water is taken on, animal and plant organisms, bacteria and germs are also taken on board as stowaways. These then land in foreign waters at the ship s destination when the water is pumped out, causing billions of pounds worth of economic and ecological damage and posing a threat to humans. The UNO is now calling this undesired spread of so-called invasive species one of the greatest threats to the maritime environment. Photo: Jamileh Javidpour, IFM-GEOMAR By 016, it will be internationally compulsory for all ships to be equipped with a ballast water management system To solve the problem, the IMO agreed the International Convention for the Control and Management of Ships Ballast Water and Sediments in 004. Following a transitional regulation currently still in force, this convention will become international law no later than 016. For shipowners and shipyards, this now means that new ships must be equipped with a ballast water management system. By 016, ships already in service will have to have been gradually fitted with this type of system depending on their ballast water capacity. IMO D standards for discharged ballast water Organism category Regulation Plankton, > 50 µm in minimum dimension < 10 cells / m 3 Plankton, µm < 10 cells / ml Toxicogenic Vibrio cholera (O1 and O139) < 1 cfu* / 100 ml or less than 1 cfu / g (wet weight) Escherichia coli < 50 cfu* / 100 ml Intestinal Enterococci < 100 cfu* / 100 ml * colony forming unit 6

7 GEA Westfalia Separator BallastMaster The solution for every size of ship and customer requirement The IMO convention sets strict guidelines for ballast water management systems: they may not harm the environment, substances used must be biodegradable and they may not present any kind of additional risk to humans, the environment or the ship. GEA Westfalia Separator BallastMaster: two key technologies for ballast water treatment In order to satisfy every detail of respective customer requirements and to enable completely neutral compliance, GEA Westfalia Separator Group has both common solutions for ballast water management in its range - BallastMaster ecop and BallastMaster ultrav. Both reliably meet the IMO standards. Whilst BallastMaster ecop is essentially based on the technical process of electrolysis, BallastMaster ultrav relies on a combination of UV-C and ultrasonic technology. Everything from a single source guarantees processneutral consultation focused solely on customer benefit With both the leading key technologies for ballast water management in their portfolio, the process specialists from GEA Westfalia Separator Group can give absolutely system-neutral advice. For customers, this means the best possible, customized solutions in accordance with objective criteria. This is because actual requirements which differ from ship to ship type, size and volume of ballast water and the shipowner s specifications -make the benefits of both system variants attractive in different ways. The advantage here is that the detailed process solution can be worked out in close collaboration to combine maximum efficiency and optimum handling with maximum economy. 7

8 GEA Westfalia Separator BallastMaster ultrav UV-C-based treatment system without the use and generation of chemicals BallastMaster ultrav is a highly efficient mechanical / physical system solution for treating ballast water including that with a high concentration of organisms and sedimentary particles. The -stage system works with mechanical pre-filtration and subsequent disinfecting of the ballast water by UV-C without the use or generation of chemicals. Initial cleaning by mechanical filtration In the first stage, a mechanical filtration process upstream removes all organisms and sedimentary particles larger than 0 microns. According to the IMO convention, this prevents sedimentary deposits accumulating in the ballast water tanks, as well as guaranteeing in the second stage an optimum result for ballast water disinfecting. The filter modules are cleaned automatically by vacuum extraction (self-cleaning). Disinfection by means of UV-C+- In the second stage, the pre-filtered ballast water is then disinfected by UV-C radiation. The monochromatic UV-C radiation (54 nm) effectively destroys organisms such as bacteria or phytoplankton. The microcavitation effected by ultrasonic guarantees that the biofilms and inorganic deposits on the UV-C tubes are cleaned off extremely efficiently and permanently. The benefits at a glance Mechanical / physical ballast water treatment process without the use and generation of chemicals UV-C radiation ensures continuously high efficiency of the disinfecting process Efficient ultrasonic cleaning of the UV tubes ensures continuously high efficiency of the disinfecting process Safe deactivation of even chlorine-resistant pathogens, e.g. Cryptosporidia Future-proof compliance with IMO directives Low maintenance requirement and incredibly easy menu control Use of corrosion-resistant materials Pore size of sintered tube filters: 0 μ Small footprint, simple installation For newbuildings and retrofit applications Reliable disinfecting to IMO standards UV-C disinfection and ultrasonic cleaning ensures consistent quality disinfecting in accordance with IMO guidelines and guarantees that harbour checks of any kind are passed without problems. BallastMaster ultrav is currently running through its third and final phase of the three-year type approval certification process required by IMO and other national authorities and will be available on the market from mid-01. 8

9 Ballasting De-ballasting Ballasting 6 Filter 0 µm 11 UV De-ballasting 7 Transfer pump 1 1 UV 3 3 Ballast pump 8 Transfer tank 13 Back-flushing water 4 By-pass 9 Transfer pump overboard 5 Stand-by 10 UV 1 14 Ballast water tank 9

10 GEA Westfalia Separator BallastMaster ecop 3-stage mechanical / electrolytic treatment process with excellent energy efficiency The BallastMaster ecop system solution is based on a mechanical / electrolytic process and treats the ballast water in three stages: filtration, disinfecting and neutralization. The disinfecting step is performed by OXIDAT, which initiates a toxic reaction to destroy the organisms and pathogens reliably. The extremely low energy consumption of BallastMaster ecop makes it especially suitable for ships with a large volume of ballast water. Its modular structure makes the system highly flexible in the retrofitting of vessels which are already at sea. BallastMaster ecop currently has IMO Basic Approval certification status. Mechanical pre-cleaning by filtration In the first treatment stage, the ballast water passes through a cartridge filter as it is taken on; this filter performs an automatic back-flush at intervals and in accordance with IMO specifications, removes all coarse particles larger than 40 microns. Disinfecting by OXIDAT In the second treatment stage, disinfecting proper is carried out by adding an active substance directly to the pipeline to the ballast water tank. OXIDAT, which is prepared on board by electrolysis from a simple salt water solution consisting of table salt and fresh water, is used as the disinfectant and is added to the ballast water taken on in a ratio of 1:50. This process which is known, tried and tested from drinking water treatment ensures that waterborne organisms, bacteria and viruses are reliably destroyed. The great advantage is that 100 percent of the OXIDAT breaks down into its starting substances under the action of UV radiation. Initially, however, the disinfectant remains in the ballast water tank where it is able to develop its long-lasting slow-release effect. This helps destroy existing deposits of organisms in the ballast tank specifically in the case of retrofits. Neutralization regulates TRO content In the third stage, when the ballast water is pumped back out, a sodium thiosulphate solution is added as required as a neutralizing agent to reduce the TRO (Total Residual Oxidants) content to the value below 0. ppm specified by the IMO. The benefits at a glance Low energy requirement, even for large treatment volumes: < 8 kw at 500 m 3 per hour Modular system structure allows flexible, decentralized positioning of the units Cartridge filter can be backflushed for high capacity: up to 1000 m 3 per hour Disinfecting only required when ballast water taken on No hazardous chemicals required: disinfecting carried out by table salt-based OXIDAT with a slow-release action Neutralization unit: TRO content reduced to below 0. ppm For newbuildings and retrofits 10

11 Ballasting De-ballasting Softened fresh water coming from: 4 Sodium thiosulfate (NaSO3) granulate 1 By-pass 13 Ballast water tank 1. Technical water tank 5 Dosing pump 14 Electrolysis unit. GEA Westfalia Separator 6 Neutralization sodium 15 Sodium chloride (NaCl) pellets SeaWaterDistiller thiosulfate solution tank 16 Dosing tank 7 Ballasting 17 Low concentrated 8 De-ballasting 9 Ballast pump 18 Dosing pump Backflushing water, overboard 10 Sodium chloride solution tank 19 Static mixer 3 De-ballasting 11 Filter 40 µm 0 Ballasting 3. Potable water system Condensate drain of charge air cooler 11 sodium hydroxide (NaOH)

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13 Retrofitting: Quick, Cheap, Safe Modular system or compact unit: the right solution for every ship performance ecop and ultrav, the two variants of the GEA Westfalia Separator BallastMaster ballast water management system, are also perfect for retrofitting seagoing vessels of an enormous variety of types and sizes. Selection of the right system depends on the design of the ship and on technical and economic specifications. GEA Westfalia Separator Group supports its customers all over the world, not only in selecting and planning the right ballast water management system, but also in selecting the competent partner to complete the installation rapidly and economically. This prevents long stays in shipyards, minimizing unavailability for charter. components makes the system of particular interest for retrofits. BallastMaster ultrav compact unit When retrofitted, the BallastMaster ultrav must naturally be integrated completely in the ballast water main line. However, the system is likewise based on a modular design concept which means optimum utilization of the existing space. This system is consequently ideal for retrofitting purposes. BallastMaster ecop modular system The modular system requires only a small space and can also be located extremely flexibly on board in a separate place. Only the cartridge filter has to be integrated directly in the primary ballast water line. This largely free choice of location for the 13

14 serv&care Proactive Service for Optimum Reliability on Board The proactive, risk-free services of serv&care optimize operating reliability and permanent availability of the drive systems. Safety first: this is precisely what the service concept serv&care stands for. Shipowners not only benefit from traditional services such as inspection, maintenance, original spare parts and repair work provided by the original manufacturer; they also benefit from proactive solutions which avoid risk, e. g. online and offline monitoring with GEA Westfalia Separator wewatch. These preventive services are the best pre-condition for a smooth operation. Enhanced process efficiency also follows from maximum operating reliability and machine availability. Accompanying modernization or upgrading to state-of-the-art technology also offer the option of boosting performance as required. Training provided on site or in the modern training centre of GEA Westfalia Separator Group ensures that the plant operator s employees receive training in the proper handling of the high-tech installations. This provides additional safety. Authorized workshops worldwide And if problems occasionally occur or if a spare part is required at short notice, the specialists are able to attend to the ships quickly. This is ensured by a global network with more than 50 sales and service companies. Authorized workshops are able to service every location in the world at short notice. 14

15 serv care serv&care accordingly makes for maximum operating reliability, machine availability, process efficiency and budget security. And these benefits are provided throughout the entire life cycle of the entire installation. In addition to traditional services such as maintenance or repair, serv&care also provides solutions which avoid risk and with which the installation availability can be proactively assured. Service from the original manufacturer: Service engineers quickly on site Extensive service network Risk avoidance through service provided by the original manufacturer Proactive solutions Upgrading to boost performance Crew training 15

16 Excellence Passion Integrity Responsibility GEA-versity GEA Group is a global mechanical engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index. GEA Mechanical Equipment GEA Westfalia Separator Group GmbH Werner-Habig-Straße 1, 5930 Oelde, Germany Tel.: , Fax: The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete inquiries. Printed on chlorine-free bleached paper Printed in Germany Subject to modification Westfalia, Westfalia Separator and wewatch are registered trademarks of GEA Mechanical Equipment GmbH. B_MA EN