Cummins has formed partnerships with Danfoss, Energys and Leclanché and created Accelera to develop net-zero and zero-carbon solutions for maritime applications including tugs, workboats, offshore support vessels and other harbour craft.
This US-based engine and generator manufacturer is looking for new power systems to offer as part of its Destination Zero strategy to reach zero emissions across its product portfolio and provide decarbonisation solutions across industries.
Cummins expects Accelera to become a global leader in zero-emissions technologies, providing battery-electric and fuel-cell solutions across commercial and industrial applications, with harbour and offshore vessels a key market.
This Indiana, US-headquartered group has turned to Leclanché for batteries and hybrid propulsion solutions and integration, Energys for fuel cells and hydrogen production technology and Danfoss’ Editron division for its electrified drivetrain solutions for global marine applications.
The partnerships come as new regulations are being enacted to encourage shipping companies and vessel owners to switch to hybrid and fully electric solutions, and to use alternative fuels to meet environmental sustainability targets and cut greenhouse gas (GHG) emissions.
“These are extremely challenging times and we need to know the technology paths to take and make sure customers have the capability to transform their operations,” says Cummins business development manager for marine technology Piotr Jacewicz.
“Although engines will remain key sources of power for a long time to come, we are looking at different directions to create a recipe of solutions for vessels. There is a long way to go, but at least we are getting ready and applying this to high-speed engines.”
Fuel solutions include sustainable biofuels such as hydrotreated vegetable oil (HVO) and fatty acid methyl ester (FAME), or methanol, ammonia and other hydrogen sources.
“We are looking at methanol/diesel dual-fuel sytms and hope to release a field-tested product in 2025,” says Mr Jacewicz.
Accelera was formed to accelerate development of products for the long-term future. “Its core is developing fuel cells,” he explains, adding this includes proton exchange membrane (PEM) and solid oxide fuel cells (SOFC).
PEM fuel cells can be applied for vessel propulsion, back-up power, during idling and for quick start-ups. “We are looking at how to develop these and apply them to marine applications,” says Mr Jacewicz. They should have marine application certification this year and produce no emissions when in use.
SOFC units are fuel-flexible as they could run on methanol, ammonia and hydrogen mixed with natural gas. They have over 75% overall efficiency, but the technology is unlikely to be commercially ready for the next five years.
“We are committed to supporting these solutions in the field and delivering the functional applications over a global perspective,” says Mr Jacewicz. When drawn on the potntal applications, he says this is defined by vessel operations, power requirements and fuel availability.
“Operational profiles are important,” he says. “Look at what the vessel does in ports and coastal operations, if it goes out to sea and if there are different operational cycles.”
After this, owners need to define different power systems on board and consider space constraints. “They can look at combinations of fuel cells and batteries, the size of fuel tanks, piping and the size of batteries required for power.”
Cummins QSK60 four stroke high speed engine at SMM other view.JPG
Cummins QSK60 four-stroke, high-speed engine could be part of a hybrid propulsion system (source: Riviera Maritime Media)
Cummins and Danfoss Editron signed a memorandum of understanding (MoU) to jointly develop a set of standard solutions for marine propulsion and focus on a new generation of variable-speed diesel generator sets, fuel cells and energy-storage packages.
Danfoss Editron division’s marne irector Erno Tenhunen says a joint prototype project was completed in 2022. “We were motivated by customers expressing their need for common solutions from our companies and expecting further standardisation of products and solutions,” he says.
“Through this partnership, we are making it easier for all marine players to decarbonise their operations. We will deliver a complex tailored system and leverage the integration work in a more organised way,” says Mr Tenhunen.
Editron is a complete electric drivetrain controlled by software to optimise each individual component for power distribution management across vessels.
“Harbour vessels, tugs and offshore support vessels have a unique set of requirements involving propulsive power, load demand, and operating profile,” says Mr Jacewicz.
“The advantage of the Cummins and Danfoss offering is that both companies’ existing product portfolio will help produce solutions that reach the desired electrification goals each operator wants toachive.”
Cummins has an MoU with Leclanché to develop a broader portfolio of integrated power solutions, including hybrid, battery only and hydrogen fuel cell packages for marine applications.
“The agreement offers a unique opportunity for both companies to collaborate, combining our capabilities to offer bespoke solutions to help decarbonise global transport and energy sectors,” says Leclanché e-mobility co-chief executive Phil Broad.
Cummins and Leclanché will work together to optimise the installation, commissioning, training, warranty and aftersales support of these power source packages.
In Q3 2022, Leclanché completed development of its third-generation marine battery system, Navius MRS-3 for electric and hybrid marine vessels. This marine rack system has a higher energy density than the second-generation unit with more flexibility for vessel electrification.
Battery string voltages of up to 1,200 VDC are available with up to a 720 A string continuous discharge current. Thenumbe of cells per module has been increased to 36 from 32 allowing each module to provide 8.7 kWh of energy.
Methanol engine partnership
Rolls-Royce Power Systems has joined forces with Woodward L’Orange and Wissenschaftlich-Technisches Zentrum (WTZ) Roßlau to develop a methanol engine for marine applications, including tugs, workboats and offshore support vessels.
This MeOHmar project received €8M (US$8.7M) of funding from the German Federal Ministry for Economic Affairs and Climate Protection to develop a concept for a high-speed internal combustion engine for vessels that can run on green methanol in a CO2-neutral manner.
This alliance brings together the manufacturer of mtu four-stroke, high-speed engines, an injection system specialist and research institute for methanol propulsion systems.
“We see great opportunities for new marine propulsion technologies and sustainable fuels, such as methanol, so we want to support the market ramp-up,” says German government maritime co-rdinatr Dieter Janecek.
In response, Rolls-Royce Power Systems alliance co-ordinator, technology strategy and sustainability, Daniel Chatterjee says, “We are convinced that with this experienced alliance of engine manufacturer, injection system supplier and research institute, we will successfully get the methanol engine on the water.”
Methanol can be produced from renewable sources and power with green hydrogen combined with CO2 from the air to form an environmental marine fuel.
“We see methanol as the future fuel for ships. It is a fuel that is already used in the chemical industry and will be produced green in the future,” says Mr Chatterjee.
Rolls-Royce project manager and MeOHmare project co-ordinator Mathias Müller says this project will consider significant changes to the engine concept.
“The focus of development activities is on redesigning the combustion process with fuel system, turbocharging and engine control as well as all fuel-interacting engine subsystems.”
Stuttart, Gemany-based Woodward L’Orange will redevelop high-performance injection systems in the project. “So far, there are no production-ready injection systems for high-speed methanol marine engines,” says Woodward L’Orange director of technology Michael Willmann.
“Methanol is a challenging fuel due to its properties. That is why new materials and injector concepts have to be introduced.” WTZ will be responsible for setting up a methanol endurance test rig, testing injection components and developing a methanol feed pump as part of the alliance.
