Charting a Course to Sustainable Maritime Energy

The NAUTILUS project is developing an integrated maritime energy system. The core of this system consists of a highly efficient Solid Oxide Fuel Cell (SOFC) coupled with a battery, using LNG as fuel for large passenger ships.

The concept, design, and operation of this integrated energy system will adhere to maritime safety codes and regulations. The ultimate goal of the project is to achieve the 2030 GHGs emission targets set by the International Maritime Organisation (IMO) strategy and virtually eliminate measurable SOx, NOx, and PM2.5 emissions.

The NAUTILUS project offers a process design concept for a novel genset integrated on-board. It includes a laboratory-scale proof-of-concept and a functional genset, both to be demonstrated in marine conditions, with the following targets:

For the Virtual Process Design Concept of On-Board Energy System:

• Provide a comprehensive design, including the Balance of Plant (BoP) and auxiliary components such as reformer, fuel storage, exhaust unit, heat exchangers, and all elements necessary to power a long-haul passenger vessel’s electric grid, including propulsion, navigation, and hotel load.
• Develop the process design for utilizing exhaust heat from the genset for on-board applications such as absorption chillers, water purification systems, swimming pools, and other hotel components.
• Present consolidated vessel integration concepts that comply with relevant maritime safety codes and requirements. Evaluate the integration of the genset with the on-board Internal Combustion Engines (ICEs).
• Create a genset simulator and a digital demonstrator of the complete energy system of the vessel. Integrate the genset simulator into the digital demonstrator, which provides real-time data on the genset and ship energy system performance under typical operational conditions. The simulation aims to characterize expected energy and emission reductions before integrating this novel genset into cruise ship power generation systems.

For the Physical Proof of Concept and Genset Demonstrator:

• Develop a laboratory Proof-of-Concept (PoC) consisting of a Large SOFC Stack Module (LSM) of 30 kWe, installed on a laboratory fuel cell test rig, coupled with a battery of a size determined by the process design and component sizing.
• Create unitized controls to operate the LSM with the battery, and test the PoC under realistic vessel load profiles and define strategies to maximize efficiency.
• Develop a containerized functional modular genset demonstrator, comprising a 60 kWe complete SOFC system, coupled with a battery of size defined by the process design and component sizing. Test the genset demonstrator to achieve an LNG-to-power efficiency of over 60% at nominal load. Evaluate its performance and efficiency at part loads and peak loads, and assess the engineering against relevant maritime safety regulations and codes. Test a 6 kWe SOFC sub-unit on an inclination platform to validate vessel safety testing.
• Characterize emissions from the genset demonstrator during operation to provide emission input data for the genset digital simulator. Demonstrate, through the ship digital demonstrator, the achievement of the 2030 emission targets of the IMO directive concerning GHGs, SOx, NOx, and PM2.5 compared to ICE-based power systems using heavy fuel oil (HFO). Analyse black carbon emissions.
• Provide a roadmap for upscaling the genset to multi-megawatt units (approximately 5 MW) and then to higher power ranges to meet the full power needs of cruise ships (typically 10 to 100 MW).
• Benchmark LNG with heavy fuel oil and other potential future marine fuels, establishing techno-economic specifications, environmental merits, and life cycle assessments.

To assess the current progress of the project, we, the NAUTILUS consortium partners, convened in Brussels for a project team meeting. The primary focus of the meeting was the second review of the project with our project officer. During this meeting, we presented the work completed up to Month 36 of the project's realization. Additionally, we provided comprehensive updates on ongoing tasks, shared insights into future project activities, and discussed the technical setup in detail.

To assess current project's progress, we, the NAUTILUS consortium partners, convened in Brussels for a project team meeting. The focus of the gathering was the second review of the project realisation with our project officer. During this meeting, we presented the work completed up to Month 36 of the project's realization. In addition, we have provided comprehensive updates on ongoing tasks and shared insights into future project activities, as well as discussing the details of technical setup.

To summarize the progress of the project, the following activities have been completed so far:

For the Virtual Process Design Concept of the On-Board Energy System (WP3):

• Review of the Process Flow Diagram (PFD), including optimizations such as cathode gas and anode gas recirculation ratios and Heat Exchanger Network (HEN).
• Conducted thermal management and integration through the 2nd HEN, achieving a total system efficiency (electrical and thermal) of >82% based on operational conditions.
• System simulation indicated excellent electrical efficiencies of >60% based on operating conditions.
• Completion of genset models, development of transient Large Stack Module (LSM) and Battery models, testing against experimental data obtained during the Proof of Concept, with good agreement, and use for prediction of the Proof-of-Concept experiments.
• Identification of applicable codes and regulations, IMO safety codes, and integration requirements for different cruise ship designs.
• Release of the first scalable multi-MW SOFC concept design, optimizing for high power density compared to current commercial systems.
• Successful testing of the first version of genset models for technical feasibility with stakeholders.

For the Physical Proof of Concept and Genset Demonstrator:

• Delivery and experimental characterization of a Large Stack Module (LSM) of 30 kW fuel cell (WP3).
• Delivery and testing of a Li-ion Battery to validate the model used in the energy management system (WP3).
• Performance of LSM/Battery coupling experiments in the Proof of Concept with the control strategies provided through the energy management unit (WP3).
• Conducted preliminary emissions analysis, began emissions characterization, and evaluated preliminary results in preparation for emissions measurements at the demonstrator (WP3).
• Realization of a unitized control algorithm for the controls of the hybrid test bench in the form of an energy management unit embedded in a specific hardware environment (WP5).
• Definition and execution of SOFC module testing on an inclination pod reflecting static and dynamic inclinations, providing important insights and recommendations into the effect of inclination on the operation of SOFCs (WP6).
• Manufacture, qualification, and installation of SOFC component stacks into the system for the demonstrator. Provided a list of specifications, technical drawings, and layout for the SOFC cabinet for integration into the demonstrator. Specified and commissioned a battery container from a subcontractor for the demonstrator (WP6).

In conclusion, the project has achieved seven project milestones so far. Furthermore, the consortium has submitted a total of nineteen deliverables to the European Commission. While the majority of these deliverables are deemed confidential due to their sensitive nature, we are delighted to offer a summary of these achievements in the following section: 

NAUTILUS Project Deliverables

This project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement No 861647.

 Stay in touch with us!

#NAUTILUS_2020 #propulsionsystem #sustainableshipping #battery #fuelcell #cruiseships