Periodic Reporting for period 3 - FASTWATER (FAST Track to Clean and Carbon-Neutral WATERborne Transport through Gradual Introduction of Methanol Fuel: Developing and Demonstrating an Evolutionary Pathway for Methanol Technology and Take-up)
Periodo di rendicontazione: 2023-06-01 al 2024-05-31
CO2 reductions from shipping, and pollutant emissions reductions are needed, including from existing vessels, i.e. including retrofitting. There are a number of alternative ways to achieve that goal. FASTWATER is meeting this target by moving shipping towards a clean and renewable fuel, namely methanol. Methanol enables an immediate reduction in pollutant emissions (effective in the short term), and offers a pathway to a climate-neutral synthetic fuel produced from renewables (effective in the long term). Methanol can thus make an immediate impact and is a future-safe fuel.
FASTWATER´s specific objectives were:
- Demonstrating the overall feasibility under operational conditions, when FASTWATER’s demo-cases test methanol in service, in a harbour tug boat, a pilot boat and a coast guard vessel; and working out the design for a methanol-powered river cruise vessel.
- Developing and demonstrating universal, scalable retrofit kits for converting ships to methanol use for a wide power range (200 kW – 4 MW)
- Developing the next generation of methanol-fuelled engines for further advances in efficiency, and further reductions in emissions and costs
- Demonstrating the complete supply chain from renewable methanol producers to ship bunkering, including setting up bunkering procedures for safe and efficient bunkering
- Working with regulatory agencies to develop rules & regulation for methanol as a fuel
- Developing a training programme for crews, gaining experience with the FASTWATER demo-cases and formulating best practices for use beyond FASTWATER
- Assessing life cycle performance to analyse investment costs, CO2 savings and pollutant reductions
FASTWATER´s specific objectives were:
- Demonstrating the overall feasibility under operational conditions, when FASTWATER’s demo-cases test methanol in service, in a harbour tug boat, a pilot boat and a coast guard vessel; and working out the design for a methanol-powered river cruise vessel.
- Developing and demonstrating universal, scalable retrofit kits for converting ships to methanol use for a wide power range (200 kW – 4 MW)
- Developing the next generation of methanol-fuelled engines for further advances in efficiency, and further reductions in emissions and costs
- Demonstrating the complete supply chain from renewable methanol producers to ship bunkering, including setting up bunkering procedures for safe and efficient bunkering
- Working with regulatory agencies to develop rules & regulation for methanol as a fuel
- Developing a training programme for crews, gaining experience with the FASTWATER demo-cases and formulating best practices for use beyond FASTWATER
- Assessing life cycle performance to analyse investment costs, CO2 savings and pollutant reductions
Vessel Conversions and Deployments:
- Harbour Tug Conversion: Completed with an efficient bunkering solution implemented. The vessel was launched to the public, with a large outreach in terms of attendees and press coverage.
- Pilot Boat conversion: Successful conversion from Diesel to Methanol. The pilot boat serves in methanol-powered operation without any major issues, for more than 2 years now.
- Coast Guard Vessel: High-speed engine conversion to dual-fuel methanol was completed, with installation on board and a successful sea trial.
- River Cruise Vessel: The profound, technically based conversion concept, risk assessment and workplan are fully elaborated and prove the feasibility of a river cruise ship conversion to methanol.
Engine and Retrofit Development
- The dual fuel methanol retrofit kit, initially developed for the medium speed engine, was extended to application on the high speed engine. The injector that was developed for the medium speed engine has been further developed, gearing up for market introduction.
- The high speed engine conversion to dual fuel operation with methanol was completed and the engine was installed on-board the coast guard vessel.
- Development of the dual-fuel medium speed engine and the MD97 engine has continued.
Training, Bunkering, and Regulations
- Crew Training: Training material for ship and shore personnel developed and widely shared, supporting knowledge transfer across the industry.
- Bunkering Solutions: Studied and recommended ship-to-ship bunkering for inland waterway vessels, with findings shared for public benefit.
- Guideline Development: Intensive efforts in creating European guidelines for methanol-powered vessel design and methanol-specific engine rooms.
Environmental and Economic Impact
- Lifecycle Performance Assessment (LCPA): Pilot boat: Up to 82.5% reduction, with profitability projected as methanol costs decrease. Tugboat: 34.7% reduction, though profitability remains tied to price structures and levies.
- Timing of conversions and future energy costs were identified as critical factors for economic viability.
Exploitation (based on the summary table in the technical report):
- ABC has developed a medium-speed methanol retrofit kit for existing and new engines, at TRL 7 in 2023 with expected revenues of €10 million in 2024 and 30 additional employees, contingent on green methanol availability.
- HZM works on a methanol injector for new or retrofitted engines, reaching TRL 7 by 2025, with plans to expand their portfolio with larger injectors and high-pressure pumps, requiring 2 new employees.
- PoAB undertakes design and risk assessments for retrofitting harbor tugs to methanol, currently at TRL 7, with potential for extending retrofit applications within its fleet by 2025.
- SCA has advanced its MD97-powered engines for marine and industrial applications, with TRL 8 and market availability in 2024.
- RISE focuses on methanol-related expertise in supply and safety for consulting purposes, targeting small vessel operators, ready for market entry by 2024.
- BAL focuses on expertise in methanol use for shipping, especially lifecycle performance assessments (LCPA), aiming to serve shipyards, operators, and public entities by 2024 with potential turnover up to €500,000 annually and up to 3 additional employees.
- MW is developing know-how for integrating methanol systems in inland waterway ships, reaching TRL 6 and targeting a launch by 2026 with potential turnover of €7-15 million and 3-4 additional employees.
- LR contributes to developing rules for methanol fuel classification and ship safety, achieving TRL 7 and positioning as an industry advisor, with services already available.
- ST builds expertise in methanol risk assessment and ship conversion, with a focus on small boats and coast guard vessels, aiming for market engagement from 2024 with potential revenue between €500,000 to €1 million.
- MTX is setting regulatory frameworks for methanol’s marine use, reaching TRL 8, and expects normalized operations by the end of 2024 with high market growth potential.
- SMA focuses on pilot boat conversion knowledge, with an aim to deploy methanol engines across its fleet (TRL 8 by 2024), though without expected additional revenue or staff increases based on methanol use.
- Harbour Tug Conversion: Completed with an efficient bunkering solution implemented. The vessel was launched to the public, with a large outreach in terms of attendees and press coverage.
- Pilot Boat conversion: Successful conversion from Diesel to Methanol. The pilot boat serves in methanol-powered operation without any major issues, for more than 2 years now.
- Coast Guard Vessel: High-speed engine conversion to dual-fuel methanol was completed, with installation on board and a successful sea trial.
- River Cruise Vessel: The profound, technically based conversion concept, risk assessment and workplan are fully elaborated and prove the feasibility of a river cruise ship conversion to methanol.
Engine and Retrofit Development
- The dual fuel methanol retrofit kit, initially developed for the medium speed engine, was extended to application on the high speed engine. The injector that was developed for the medium speed engine has been further developed, gearing up for market introduction.
- The high speed engine conversion to dual fuel operation with methanol was completed and the engine was installed on-board the coast guard vessel.
- Development of the dual-fuel medium speed engine and the MD97 engine has continued.
Training, Bunkering, and Regulations
- Crew Training: Training material for ship and shore personnel developed and widely shared, supporting knowledge transfer across the industry.
- Bunkering Solutions: Studied and recommended ship-to-ship bunkering for inland waterway vessels, with findings shared for public benefit.
- Guideline Development: Intensive efforts in creating European guidelines for methanol-powered vessel design and methanol-specific engine rooms.
Environmental and Economic Impact
- Lifecycle Performance Assessment (LCPA): Pilot boat: Up to 82.5% reduction, with profitability projected as methanol costs decrease. Tugboat: 34.7% reduction, though profitability remains tied to price structures and levies.
- Timing of conversions and future energy costs were identified as critical factors for economic viability.
Exploitation (based on the summary table in the technical report):
- ABC has developed a medium-speed methanol retrofit kit for existing and new engines, at TRL 7 in 2023 with expected revenues of €10 million in 2024 and 30 additional employees, contingent on green methanol availability.
- HZM works on a methanol injector for new or retrofitted engines, reaching TRL 7 by 2025, with plans to expand their portfolio with larger injectors and high-pressure pumps, requiring 2 new employees.
- PoAB undertakes design and risk assessments for retrofitting harbor tugs to methanol, currently at TRL 7, with potential for extending retrofit applications within its fleet by 2025.
- SCA has advanced its MD97-powered engines for marine and industrial applications, with TRL 8 and market availability in 2024.
- RISE focuses on methanol-related expertise in supply and safety for consulting purposes, targeting small vessel operators, ready for market entry by 2024.
- BAL focuses on expertise in methanol use for shipping, especially lifecycle performance assessments (LCPA), aiming to serve shipyards, operators, and public entities by 2024 with potential turnover up to €500,000 annually and up to 3 additional employees.
- MW is developing know-how for integrating methanol systems in inland waterway ships, reaching TRL 6 and targeting a launch by 2026 with potential turnover of €7-15 million and 3-4 additional employees.
- LR contributes to developing rules for methanol fuel classification and ship safety, achieving TRL 7 and positioning as an industry advisor, with services already available.
- ST builds expertise in methanol risk assessment and ship conversion, with a focus on small boats and coast guard vessels, aiming for market engagement from 2024 with potential revenue between €500,000 to €1 million.
- MTX is setting regulatory frameworks for methanol’s marine use, reaching TRL 8, and expects normalized operations by the end of 2024 with high market growth potential.
- SMA focuses on pilot boat conversion knowledge, with an aim to deploy methanol engines across its fleet (TRL 8 by 2024), though without expected additional revenue or staff increases based on methanol use.
Progress beyond State of the art:
• Development, implementation and demonstrating the feasibility of methanol retrofit kits
• The converted methanol tug is worldwide the first of its kind
• The successful conversion of the pilot boat to use 97% of green methanol
• Reliable operation of the converted methanol pilot boat in daily operation
• A finished set of regulations for the storage of methanol on board inland waterway vessels and the use of methanol in engines on inland waterway vessels
• Training material was developed and applied for crew and on-shore personnel.
• Recommendations on the most interesting concepts to be further developed, to allow single-fuel operation on methanol.
Impact:
FASTWATER advanced the commercialization of methanol-fuelled technologies for maritime use, including retrofit kits, specialized injectors and new engine models. Partners ABC and SCA saw increased demand for methanol engines making up a growing share of sales, while regulatory progress, such as Belgium’s tax exemption for methanol, facilitated adoption. MW’s feasibility study supported methanol conversion for river cruise vessels, and the pilot boat launch engaged key industry stakeholders. The project also influenced new safety regulations for methanol in inland vessels and developed important training programs. Several related projects and research initiatives emerged, focusing on maximizing methanol’s benefits and developing pure methanol combustion for large engines.
• Development, implementation and demonstrating the feasibility of methanol retrofit kits
• The converted methanol tug is worldwide the first of its kind
• The successful conversion of the pilot boat to use 97% of green methanol
• Reliable operation of the converted methanol pilot boat in daily operation
• A finished set of regulations for the storage of methanol on board inland waterway vessels and the use of methanol in engines on inland waterway vessels
• Training material was developed and applied for crew and on-shore personnel.
• Recommendations on the most interesting concepts to be further developed, to allow single-fuel operation on methanol.
Impact:
FASTWATER advanced the commercialization of methanol-fuelled technologies for maritime use, including retrofit kits, specialized injectors and new engine models. Partners ABC and SCA saw increased demand for methanol engines making up a growing share of sales, while regulatory progress, such as Belgium’s tax exemption for methanol, facilitated adoption. MW’s feasibility study supported methanol conversion for river cruise vessels, and the pilot boat launch engaged key industry stakeholders. The project also influenced new safety regulations for methanol in inland vessels and developed important training programs. Several related projects and research initiatives emerged, focusing on maximizing methanol’s benefits and developing pure methanol combustion for large engines.