Innovative maritime power-to-X system for zero-emissions shipping corridors

The £2.6M (US$3.3M) UK Department of Transport-funded project, presented at Riviera’s Maritime Decarbonisation Conference Americas in Houston, aims to establish a zero-emissions shipping corridor between Northern Ireland and England.

The project introduces several key technical innovations aimed at enhancing efficiency and sustainability, said B9 Energy Storage managing director David Surplus. B9 Energy Storage is the lead partner and patent holder of the Power-to-X maritime methanol reforming and CO2 recycling system.

One such innovation is the direct connection between offshore windfarms and electrolysers, which effectively bypasses grid constraints and optimises energy use. Instead of traditional combustion, the project employs onboard methanol reforming, which is complemented by a CO2 capture and recycling system to minimise emissions. Additionally, an ISO tank-based bunkering solution is implemented to streamline fuel storage and distribution.

The system boasts impressive efficiency metrics across various components. The electrolyses achieve 70% efficiency, with waste heat repurposed for district heating, enhancing overall energy utilisation. The reformer operates at 80% efficiency, while the fuel cells achieve 55% efficiency. Collectively, these components contribute to an overall system efficiency of 44%. Notably, the integration of hydrogen from water provides a ‘virtual’ efficiency boost, raising it to 66%.

Economically, the project offers significant advantages said Mr Surplus. By eliminating the €840 (US$887) per tonne cost of methanol from conventional CO2 sourcing, it reduces operational expenses substantially. The design ensures minimal capital expenses for the balance of plant and nearly eliminates ongoing CO2 costs over the project’s 30-year lifespan. These efficiencies position the project to potentially achieve fossil fuel price parity ahead of alternative solutions.

This project addresses several pressing challenges within the industry, he added. It tackles windfarm curtailment issues, which can reach up to 40% in some regions, by optimising energy use through direct connections. It also mitigates limitations related to green or biogenic CO2 availability and grid connection constraints. Furthermore, the project supports mid-life vessel compliance with EEXI and CII regulations, ensuring vessels remain operationally viable and environmentally compliant.

"We have funding to model a standard roro freight ferry carrying 400 trailers between Larne and Liverpool, comparing current fossil fuel operations with our methanol system," Mr Surplus explained, noting the project includes partners DFDS Seaways, Lloyd’s Register, Port of Larne, Mutual Energy and Net Zero Industry Innovation Centre.