The marine industry faces significant challenges in meeting the ambitious decarbonization targets set by the International Maritime Organization (IMO). In this context, Solid Oxide Fuel Cells (SOFC) are emerging as a promising alternative to traditional diesel engines. SOFCs are electrochemical devices that generate electrical energy by oxidizing fuel, offering high efficiency, reduced emissions, high-quality heat, and with some modifications, can be operated with a range of low-emission fuels.
For the past four years, the NAUTILUS project has focused on the development, evaluation, and validation of a highly efficient power generation system designed for large passenger ships. Central to this technological solution is a hybrid system consisting of SOFC and battery units. As the NAUTILUS project nears its conclusion at the end of 2024, several key activities are ongoing.
The NAUTILUS project has already demonstrated a physical proof-of-concept in laboratory conditions with a 30 kW SOFC unit and a Li-ion battery. The next step involves assembling a physical demonstrator in August 2024 at the German Aerospace Center (DLR) in Stuttgart. This demonstrator will feature a 60 kW SOFC system delivered by the Italian project partner, SolydEra, along with a battery container provided by MAN Energy Solutions and a control unit developed by RWTH Aachen University. This system will undergo rigorous testing and operation over a three-month period between September and December 2024 under various load scenarios, with emissions measurement performed by a team of scientists from Lund University.
Installation and Integration
The SOFC system, measuring 2.8 meters in length, 2.1 meters in width, and 2.9 meters in height, has already been delivered to DLR Stuttgart and placed at the future demonstrator test site. The system's main inputs are air and fuel (natural gas), with the main outputs being power, heat (for potential hot water production), and exhaust. To cater to these inputs/outputs, auxiliaries are included with the SOFC system, such as an air blower, filters, compressor (increasing nominal gas pipe pressure to the required value), AC grid connection (required for the backup circuit), as well as DC/DC converters. Under real conditions, the heat produced by the system will be consumed by hotel amenities on the passenger ship.
Currently, the SOFC system is being installed at the demonstration site. This installation phase involves not only the unloading and proper positioning of the unit but also the connection of all additional systems or interfaces. These include fuel supply (natural gas), electricity connections, and a drip point for condensate water.
Key Features of the NAUTILUS Project's SOFC System
The SOFC system in the NAUTILUS project is designed for high electrical generation efficiency, capable of both alternating current (AC) and direct current (DC) configurations. It can also function as a Combined Heat and Power (CHP) system, leveraging its high operating temperature to produce both electricity and high-quality heat. The system is adaptable, capable of operating with various fuel gases such as natural gas and biogas, and can be scaled up by installing multiple units in parallel. For the demonstrator phase, the SOFC system will be fuelled by natural gas.
The 60 kW SOFC system comprises of 40 proprietary 1.7 Kw DC stacks, manufactured by SolydEra at their automated industrial production plant in Pergine, Italy. The stacks use planar Anode Supported Cells (ASC) with a thin electrolyte, allowing them to operate efficiently in a temperature range of 650-800°C. The proprietary sealing material and optimized interconnect coating ensure tightness, robustness, and extended lifetime.
The deployment of the SOFC system represents a significant milestone in the demonstrator’s assembly and evaluation of the plausibility of the highly efficient SOFC technology for maritime use, together with the targeted emission reduction.
This project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement No 861647.
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NAUTILUS is a short for Nautical Integrated Hybrid Energy System for Long-haul Cruise Ships.
This project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement No 861647.