Periodic Reporting for period 3 - Nautilus (Nautical Integrated Hybrid Energy System for Long-haul Cruise Ships)
Periodo di rendicontazione: 2023-07-01 al 2024-12-31
Maritime transport is among the leading sources of greenhouse gases and pollutants which are estimated to cause 50,000 premature annual deaths and €58 billion annual cost to the society in the EU. With the International Maritime Organization (IMO) regulations coming in force, marine transport needs new energy solutions for emissions reduction. Passenger ships are the most affected as they have growing pressure from their customers and habitants near ports for a clean environment. To address these challenges, this project has developed, evaluated and validated a highly efficient and dynamic integrated marine energy system fuelled by Liquefied Natural Gas (LNG) for long-haul passenger ships. This energy system, responsible to cater for all heat & power needs of a vessel, consists of a Solid Oxide Fuel Cell (SOFC)-battery hybrid genset with coupling with the existing Internal Combustion Engine (ICE) based generators and gradually replacing these ICEs. The project developed and delivered a complete process design and digital demonstrator of a fully integrated on-board energy system of a size between 5 and 60 MW for two types of cruise ships: 1000 and 5000+ passenger vessels. A physical proof-of-concept (PoC 30 kWe SOFC+battery) as well as a functional demonstrator (60 kWe SOFC+battery) of the hybrid genset were developed and operated to validate the design and operation strategies. The digital design and the physical demonstrator were evaluated against the marine safety regulations. The project brings in a consortium of key actors in maritime passenger transport including ship operators, ship builders, marine engine builder, marine regulatory company, and technology developers supported by research organizations from across the Europe. Together they validated this integrated energy system to comply with the IMO targets of 2030 and beyond. Besides, regulatory framework, emission analysis, lifecycle assessment and feasibility of fuel flexibility were addressed.
The NAUTILUS project is designed to develop and test a disruptive low-emission Genset for large passenger ships, by developing an innovative Solid Oxide Fuel Cells (SOFC) and battery hybrid to drastically reduce CO2 and non-CO2 emissions. An SOFC system design and a concept for ship integration at the Multi-MW scale was produced that yields above 60% LHV electrical efficiency at full load in beginning-of-life condition, and accounts for its operation until SOFC end-of-life. Valorization of the heat produced for ship hot water production enables a net combined efficiency of 77% (LHV). Experimental results for SOFC Large Stack Module (LSM) characterization and LSM/Battery Proof of Concept were used to calibrate design models, including specially developed energy management system. Marinization aspects were considered by experiments of SOFC-inclination and safety aspects were investigated in a HAZID analysis.
The SOFC & Battery Genset’s modular implementation was analysed with the Virtual Genset Simulator, which summarizes the design considerations and provides a basis for energy scenario simulations by shipyards. In-depth electrical and thermal vessel integration studies performed by shipyards include estimated real component genset sizing, auxiliaries, fuel supply and exhaust venting systems, as well as on-board arrangement strategies. As a result, design drawings of piping and grid arrangements as well as maintenance considerations were produced in a deck-layout of separate fuel cell- and batteries rooms. Simulations to analyse emission and energy efficiency for three different design integration scenarios were performed to identify fuel savings and emission reductions with the newly developed genset utilizing the digital twins of the shipyards developed for this purpose.
Design, manufacturing and commissioning of the SOFC system and of the battery and controls container components were completed and integrated together with the energy management system (EMS) unit in the SOFC/battery genset demonstrator, which attained its launch event at the demonstrator site on October 29th, 2024. The genset demonstrator delivered 64.6 MWh of electric power to the grid from September to December 2024 and demonstrated a peak efficiency of 61.9% (LHVDC) and 60.1% (LHVAC), significantly outperforming conventional gensets typically operating at 40 to 45% LHV.
The technology impact analyses were carried out, with a study of genset performance with future fuels showing highest electrical efficiency for LNG compared to other future fuels. The levelized cost of energy (LCOE) produced onboard is highly competitive at 0.247 EUR/kWh. The on-site emissions measurement campaign validated a 30% reduction in CO2 emissions compared to internal combustion engines (ICE) operating with heavy fuel oil (HFO), negligible methane slip and an outstanding 95% reduction in non-CO2 pollutants, even in part-load operations—an unprecedented achievement in maritime energy systems. The lifecycle assessment (LCA) with five fuels (methane, methanol, diesel, ammonia, and hydrogen) predicts a 30% lower operational global warming potential due to CO2 emission compared to the HFO ICE.
A health impact assessment was conducted from which it was estimated that shipping-related PM2.5 emissions account for up to 2.3% of premature deaths and 7.3% of childhood asthma cases in certain European port cities. These health impacts also translate into substantial societal costs, including increased healthcare expenses, reduced workforce productivity, and diminished quality of life. Implementing stricter emission control measures, such as low-sulfur fuels and the establishment of emission control areas, has the potential to reduce premature deaths related to shipping emissions by up to 50% and lower asthma cases by 30%. Additionally, advanced technologies like solid oxide fuel cells (SOFC) could cut emissions of PM2.5 NOₓ, and SO2 by over 99%, providing significant health and societal benefits.
Finally, The NAUTILUS project’s results have been widely presented in leading scientific journals and conferences for SOFC technology, battery and energy management as well as transportation research, and a novel format was introduced to the European Fuel Cell Electrolysis Forum (EFCF) with the first Sustainable Shipping Days (SSD). For an overview of the results and their exploitation and dissemination, please refer to Deliverable D8.5
The SOFC & Battery Genset’s modular implementation was analysed with the Virtual Genset Simulator, which summarizes the design considerations and provides a basis for energy scenario simulations by shipyards. In-depth electrical and thermal vessel integration studies performed by shipyards include estimated real component genset sizing, auxiliaries, fuel supply and exhaust venting systems, as well as on-board arrangement strategies. As a result, design drawings of piping and grid arrangements as well as maintenance considerations were produced in a deck-layout of separate fuel cell- and batteries rooms. Simulations to analyse emission and energy efficiency for three different design integration scenarios were performed to identify fuel savings and emission reductions with the newly developed genset utilizing the digital twins of the shipyards developed for this purpose.
Design, manufacturing and commissioning of the SOFC system and of the battery and controls container components were completed and integrated together with the energy management system (EMS) unit in the SOFC/battery genset demonstrator, which attained its launch event at the demonstrator site on October 29th, 2024. The genset demonstrator delivered 64.6 MWh of electric power to the grid from September to December 2024 and demonstrated a peak efficiency of 61.9% (LHVDC) and 60.1% (LHVAC), significantly outperforming conventional gensets typically operating at 40 to 45% LHV.
The technology impact analyses were carried out, with a study of genset performance with future fuels showing highest electrical efficiency for LNG compared to other future fuels. The levelized cost of energy (LCOE) produced onboard is highly competitive at 0.247 EUR/kWh. The on-site emissions measurement campaign validated a 30% reduction in CO2 emissions compared to internal combustion engines (ICE) operating with heavy fuel oil (HFO), negligible methane slip and an outstanding 95% reduction in non-CO2 pollutants, even in part-load operations—an unprecedented achievement in maritime energy systems. The lifecycle assessment (LCA) with five fuels (methane, methanol, diesel, ammonia, and hydrogen) predicts a 30% lower operational global warming potential due to CO2 emission compared to the HFO ICE.
A health impact assessment was conducted from which it was estimated that shipping-related PM2.5 emissions account for up to 2.3% of premature deaths and 7.3% of childhood asthma cases in certain European port cities. These health impacts also translate into substantial societal costs, including increased healthcare expenses, reduced workforce productivity, and diminished quality of life. Implementing stricter emission control measures, such as low-sulfur fuels and the establishment of emission control areas, has the potential to reduce premature deaths related to shipping emissions by up to 50% and lower asthma cases by 30%. Additionally, advanced technologies like solid oxide fuel cells (SOFC) could cut emissions of PM2.5 NOₓ, and SO2 by over 99%, providing significant health and societal benefits.
Finally, The NAUTILUS project’s results have been widely presented in leading scientific journals and conferences for SOFC technology, battery and energy management as well as transportation research, and a novel format was introduced to the European Fuel Cell Electrolysis Forum (EFCF) with the first Sustainable Shipping Days (SSD). For an overview of the results and their exploitation and dissemination, please refer to Deliverable D8.5
The project delivered three key results to bring forward an energy system offering significantly higher efficiency than state-of-the-art maritime engine technology: A proof of concept, a digital twin simulator and a demonstrator. All three milestones were reached, with proof of concept results demonstrated at the laboratory scale, digital twin simulators produced for ship designs with the new technology, and the demonstrator operated between September and December 2024. Increasing public awareness is followed by an increasing demand for clean travelling options. Whereas the freight shipping industry has already largely moved to the Asian market, the European cruise shipping industry continues to command 95% of the market share in the leisure and travelling segment. Europe has the opportunity to assume a leading role in the innovative shipping operations that result in a significantly improved climate balance.