Periodic Reporting for period 3 - HCR (Market maturation of the first on-board autonomous biofouling cleaning system to keep ship’s hull clean at all times)
Okres sprawozdawczy: 2020-04-01 do 2022-09-30
Environmental awareness has grown in the shipping sector alongside the enforcement of stricter regulations to reduce ship emissions and protect the maritime environment
2. Indeed, since 2008 highly toxic compounds, as Tributyltin (TBT), were banned from antifouling coatings. This, in parallel with the need to increase the competitiveness of the sector, is driving a strong demand of cost-effective solutions towards greener shipping, representing a business opportunity valued > €13 billion/ year
3. The highest potential has been attributed to solutions increasing fuel efficiency, enabling both fuel consumption and ship emissions reduction.
Cliin has designed, developed and prototyped the first on-board hull cleaning solution - the HCR (Hull Cleaning Robot) system – which consists of an on-board mobile docking station and a small and light autonomous underwater cleaning robot permanently installed on the ship. Through a continuous light and gentle cleaning, adequate to remove light slime and more tough fouling as well, the optimal hull performance is maintained continuously.
The HCR system provides easy access to hull cleaning at ships. Below is a list of benefits of the HCR:
• Permanently installed on the ship
• Reduces fuel consumption up to 20% between dry dock vs. on-demand cleaning
• Reduces ship maintenance and repair by 50% vs. on-demand cleaning
• Net savings up to 81% over 5 years between mandatory dry-dockings vs. on-demand cleaning
• Reduces emission of GHG emissions by 95% vs. on-demand cleaning
• Acts as a perfect match with all coatings, including nontoxic coatings (hard coating, Silicone based)
• Eliminates the transportation of invasive species on the hull
• Avoids port restrictions, as cleaning can be done at open sea
• No damage of the coating system due to gentle cleaning.
The main objective of the HCR project is to automate – to arrive to a final design –, test and validate the benefits of the system in a real-life like test setup, in order to generate solid performance documentation for product certification and business case references, bringing HCR to market readiness. Danish shipping companies J. Lauritzen, Norden, Ultrabulk & Maersk have participated in continuous workshops to support and validate the test program.
2. Indeed, since 2008 highly toxic compounds, as Tributyltin (TBT), were banned from antifouling coatings. This, in parallel with the need to increase the competitiveness of the sector, is driving a strong demand of cost-effective solutions towards greener shipping, representing a business opportunity valued > €13 billion/ year
3. The highest potential has been attributed to solutions increasing fuel efficiency, enabling both fuel consumption and ship emissions reduction.
Cliin has designed, developed and prototyped the first on-board hull cleaning solution - the HCR (Hull Cleaning Robot) system – which consists of an on-board mobile docking station and a small and light autonomous underwater cleaning robot permanently installed on the ship. Through a continuous light and gentle cleaning, adequate to remove light slime and more tough fouling as well, the optimal hull performance is maintained continuously.
The HCR system provides easy access to hull cleaning at ships. Below is a list of benefits of the HCR:
• Permanently installed on the ship
• Reduces fuel consumption up to 20% between dry dock vs. on-demand cleaning
• Reduces ship maintenance and repair by 50% vs. on-demand cleaning
• Net savings up to 81% over 5 years between mandatory dry-dockings vs. on-demand cleaning
• Reduces emission of GHG emissions by 95% vs. on-demand cleaning
• Acts as a perfect match with all coatings, including nontoxic coatings (hard coating, Silicone based)
• Eliminates the transportation of invasive species on the hull
• Avoids port restrictions, as cleaning can be done at open sea
• No damage of the coating system due to gentle cleaning.
The main objective of the HCR project is to automate – to arrive to a final design –, test and validate the benefits of the system in a real-life like test setup, in order to generate solid performance documentation for product certification and business case references, bringing HCR to market readiness. Danish shipping companies J. Lauritzen, Norden, Ultrabulk & Maersk have participated in continuous workshops to support and validate the test program.
As per the Description of Action (DoA), the following three (3) overarching objectives (Automation, Overall Costs, End-user acceptance) is described for the project. The below objectives remain unchanged, though the actual results and methods of validation have been mitigated due to COVID-19.
Automation: To convert the remote-controlled cargo hold robot, CLIIN has used well-proven technology to enable the automation of the system. Every ship type has a unique hull design, and the HCR will be programmed to clean along a predefined route identified from the individual ships drawing. The activities performed to enable following a route, has been proven through testing.
Results on Automation:
a. The initial concept of loading the vessel drawings into the robot, has been conceptualized and further specified through customer workshops.
b. The winch controls the main navigation functions combined with data from the robot.
c. Combined with cameras and operator interface, this provides satisfying measures for safe assisted navigation.
d. The workshops have provided important information on the final navigation concept, which is simpler to setup and use and more robust in the end-user operation, with a satisfying error margin on the robot accuracy.
2. Overall Cost: CLIIN reduces the manufacturing costs without compromising the performance of the HCR. This is achieved through an improved design, implementation of design for manufacturing, batch production and the set-up of an efficient supply chain.
3. End-user acceptance: The HCR concept constitutes a paradigm shift and a completely new approach to biofouling in the shipping industry. CLIIN wanted to demonstrate the HCR system on ships in fully operational environments with end-users, to generate solid data on its economic and environmental benefits. However, we needed to find other methods to obtain this knowledge on the product performance and end-user acceptance, as COVID has prevented the on-board demonstrations, and still does.
Results on the End-user acceptance:
a. As the HCR is a paradigm shift from reactive to proactive cleaning of the biofouling on the vessel hull, we needed solid data to back the concept itself.
b. Acceptance through customer and partner workshops
i. The main concerns and critical findings in the workshops with Maersk, Norden and Ultra Bulk was the identification of critical performance measures, such as; System operation, availability when idle, technical abilities of core robot: paint scratching, passing welding seams and ability to adhere to the hull in strong currents.
Exploitation of HCR concept
It is expected that implementation of HCR will result in a saving potential from cradle to grave (25 years) of €12.95 million per ship as a result of i) less expensive coating system
ii) reduction in fuel consumption iii) decreased operational costs for maintenance and iv) less days for off-hire due to a 10-year frequency of dry dockings – as opposed to the current 5-year interval.
Additionally, the ship owners/operators will gain a greener company profile which may let them harvest further financial benefits and support them in meeting the increased requirements within environmental regulations.
Dissemination of HCR concept
CLIIN plans to leverage existing channels in the dissemination of the HCR concept.
CLIIN’s website contains a subsite concerning Robotic Antifouling which relates directly to the results of this project and the dissemination of results and benefits of implementing the HCR. CLIIN’s Linkedin page with more than 1400 followers along with newsletters will be used to engage with relevant professional audience and distribute HCR related information.
CLIIN will participate in relevant industry events (e.g. SMM Hamburg, Nor Shipping Oslo, Posedonia Athens) to promote the HCR system to potential end-users through presentation of the project results. CLIIN will seek to have articles focusing on the demonstration results published in relevant industry media and through State of Green, Denmark’s official green marketing consortium, exposing green solutions to a worldwide audience.
Automation: To convert the remote-controlled cargo hold robot, CLIIN has used well-proven technology to enable the automation of the system. Every ship type has a unique hull design, and the HCR will be programmed to clean along a predefined route identified from the individual ships drawing. The activities performed to enable following a route, has been proven through testing.
Results on Automation:
a. The initial concept of loading the vessel drawings into the robot, has been conceptualized and further specified through customer workshops.
b. The winch controls the main navigation functions combined with data from the robot.
c. Combined with cameras and operator interface, this provides satisfying measures for safe assisted navigation.
d. The workshops have provided important information on the final navigation concept, which is simpler to setup and use and more robust in the end-user operation, with a satisfying error margin on the robot accuracy.
2. Overall Cost: CLIIN reduces the manufacturing costs without compromising the performance of the HCR. This is achieved through an improved design, implementation of design for manufacturing, batch production and the set-up of an efficient supply chain.
3. End-user acceptance: The HCR concept constitutes a paradigm shift and a completely new approach to biofouling in the shipping industry. CLIIN wanted to demonstrate the HCR system on ships in fully operational environments with end-users, to generate solid data on its economic and environmental benefits. However, we needed to find other methods to obtain this knowledge on the product performance and end-user acceptance, as COVID has prevented the on-board demonstrations, and still does.
Results on the End-user acceptance:
a. As the HCR is a paradigm shift from reactive to proactive cleaning of the biofouling on the vessel hull, we needed solid data to back the concept itself.
b. Acceptance through customer and partner workshops
i. The main concerns and critical findings in the workshops with Maersk, Norden and Ultra Bulk was the identification of critical performance measures, such as; System operation, availability when idle, technical abilities of core robot: paint scratching, passing welding seams and ability to adhere to the hull in strong currents.
Exploitation of HCR concept
It is expected that implementation of HCR will result in a saving potential from cradle to grave (25 years) of €12.95 million per ship as a result of i) less expensive coating system
ii) reduction in fuel consumption iii) decreased operational costs for maintenance and iv) less days for off-hire due to a 10-year frequency of dry dockings – as opposed to the current 5-year interval.
Additionally, the ship owners/operators will gain a greener company profile which may let them harvest further financial benefits and support them in meeting the increased requirements within environmental regulations.
Dissemination of HCR concept
CLIIN plans to leverage existing channels in the dissemination of the HCR concept.
CLIIN’s website contains a subsite concerning Robotic Antifouling which relates directly to the results of this project and the dissemination of results and benefits of implementing the HCR. CLIIN’s Linkedin page with more than 1400 followers along with newsletters will be used to engage with relevant professional audience and distribute HCR related information.
CLIIN will participate in relevant industry events (e.g. SMM Hamburg, Nor Shipping Oslo, Posedonia Athens) to promote the HCR system to potential end-users through presentation of the project results. CLIIN will seek to have articles focusing on the demonstration results published in relevant industry media and through State of Green, Denmark’s official green marketing consortium, exposing green solutions to a worldwide audience.
After upcoming onboard testing, CLIIN will present a robot that will completely change the way hull cleaning is done. CLIIN’s proactive cleaning approach, will significantly reduce fuel consumption of ships and thereby minimize the environmental footprint of the shipping industry.
For the society, the main direct benefits provided by the HCR system are related to the highest safety, security and social standards, enabled by the transformation of manual/ diving-based cleaning operations into remotely controlled semi-autonomous ones, which reduces the exposure to fatalities and accidents. Furthermore, the reduced drag of a clean hull will lead to lower fuel consumption, that in turn will lead to fewer greenhouse gasses emitted. From a global economy perspective, the increase in the profitability of the companies (detailed in the sub-section above) will enable a reduction of transport costs, alleviating one of the major constraints to trade, thereby creating opportunities to access foreigner countries and promote job creation.
For the society, the main direct benefits provided by the HCR system are related to the highest safety, security and social standards, enabled by the transformation of manual/ diving-based cleaning operations into remotely controlled semi-autonomous ones, which reduces the exposure to fatalities and accidents. Furthermore, the reduced drag of a clean hull will lead to lower fuel consumption, that in turn will lead to fewer greenhouse gasses emitted. From a global economy perspective, the increase in the profitability of the companies (detailed in the sub-section above) will enable a reduction of transport costs, alleviating one of the major constraints to trade, thereby creating opportunities to access foreigner countries and promote job creation.