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ENERGIX-Stort program energi

Electric solutions enabling zero emission ferry

Alternative title: Elektriske løsninger for å muliggjøre nullutslipps-ferger

Awarded: NOK 5.4 mill.

Project Number:

269136

Project Period:

2017 - 2019

Funding received from:

In order to increase the number of zero emission ferries globally, more ferries must run on electricity. A ferry installed with electric energy storage will charge at quay and discharge during transit. To minimise energy loss, this transmission of energy should involve the lowest number of components as possible. It should also be robust to avoid delays and outages of the ferry service. The transmission involves going from AC on the shore connection to DC on the batteries. In this project we have developed a solution that makes this conversion more energy efficient, cheaper and more robust than existing solutions. We have verified the losses that have been eliminated, and removed one conversion from the system. With this we have removed a significant cost, and the probability for faults and downtime has been reduced. The energy loss through the battery has been reduced utilizing more efficient energy conversion. The first system has been delivered and is in operation. The energy storage in the ferry consists of batteries, and the cost of batteries make up the major part of the cost of the electrical system. Reducing the cost of batteries will therefore be crucial to drastically increase the number of zero emission ferries. In this project we have investigated whether batteries from mass production intended for land-based applications can be utilised in the maritime sector. The rules and regulations place higher demands on maritime applications compared to current applications developed for mass production. The project has developed a platform for mass production that satisfies all the regulations, reduces the cost of batteries, while still providing high quality. The platform is also flexible enough to handle introduction of new battery types, as the technology is developing fast. A prototype has been developed for running tests focusing on safety, efficiency and robustness. The equipment has been tested for safety and for compliance with maritime environments. The tests have been witnessed by DNV GL and Norsk Sjøfart. Delivery of first project: February 2019. To keep the operation up and running, a zero emission ferry must have at least two drive trains and two battery packs in case of a fault. When the ferry crosses back and forth, the two power trains will experience different energy loads. If the battery packs experience different energy discharging, the total size of the battery pack must be over-dimensioned, and the lifetime will be reduced. Therefore we interconnect the two battery packs and powertrains, so that the charge cycles can be shared equally. However, the two sides must be separated in case of a fault. This maintains safety and avoids outages. If the ferry loses both power train there is a risk of collision, material damages, injuries and in a worst case scenario, also casualties. In this project we investigate different fault scenarios and develop safety components that enable a disconnection between the two systems before a fault on one side effects the other side. The solution is simple, robust, cost effective and safe. In parallel, designated algorithms have been developed to control equal load on all batteries. Simulations and software testing and theoretical calculations of the protection functions have been performed. A full scale prototype has been built and tests have verified the system. The first project has been delivered and is in operation. Onboard a zero emission ferry the power system itself contains several power conversions from shore via the batteries through to the propeller. The energy lost and the risk of component failure through transmission, increase with the number of conversions that the electric energy passes through. In this project we have developed a power management system and power components that reduce the energy loss. By developing passive power conversion elements and reducing the number of conversions, the energy lost can potentially be reduced by 50 per cent. Lower energy loss will reduce the required energy storage capacity and reduce the cost of the system both in the investment phase and through the life cycle. Theoretical simulations and testing on a prototype has been completed. The first delivery planned in February 2019 will enable us to verify the results during operation.

With this project RRM has been enabled to deliver energy storage as a part of the total electric system. The market for marine energy storage and electrical/hybrid propulsion for ships is expected to grow significantly in the coming years. The company will continue to support energy storage development, and a new division called Energy Storage has been created. The division will conduct research on battery technology, develop new products and deliver solutions to customers. The local competence on battery technology and the development of energy storage for maritime usage has increased and will be strengthen through continuous development of energy storage solutions within the company. It is expected that realizing the innovations combined with the advantages provided by Rolls-Royce novel power system will boost ferry production in Norway.

The electric system as a whole or its sub-systems or components will be applicable for several classes of ferries, including double-ended ferries, Ro-Pax and cruise ferries. The project activities corresponding to the system parts are: - Low-cost energy storage - Power management system with intelligent energy balancing - Low-cost and high efficiency charging system - Optimized on-board distribution system Further activities cover: - approval and testing, - results dissemination and patenting Important activity is cooperation with 'Ocean Space Exploration Vessel' programme, which implies technology transfer and cross-implementation of ideas and concepts. The innovations will enable value creation through improved operational efficiency and reduced purchase and installation costs. This will lead to cost savings and a reduction or complete removal of local emissions. This makes the overall environmental effect of the innovations quite high; for example, the expected annual CO2 emissions reduction per ferry would be 550-600 tons. Assuming an installation rate of 10-15 ferries per year, the total reduction in CO2 emissions would be equivalent to 5,800 - 8,700 tons/year.

Funding scheme:

ENERGIX-Stort program energi