COLD IRONING

A new eco-compatible solution for powering ships at berth

COLD IRONING is the process of providing shore-side electrical power to a ship at berth while its engines are turned off and literally cold and the ship is like an enormous iron. This process can also be called a High Voltage Shore Connection (HVSC) or Alternative Maritime Power. Cold Ironing involves power supply at the jetty to ships at berth for the correct use of on-board services while keeping the ships engines turned off, minimizing the amount of pollution generated.

V.T.P. Engineering, formed by a partnership between Venezia Terminal Passeggeri S.p.A. and Abacoingegneria Treviso s.r.l., proposes an innovative and environmentally friendly solution to the problem of supplying power to ships from jetties when they are at port.

Solutions used to date

Current Cold Ironing solutions involve the supply of power to ships from the national mains supply. Cold Ironing is a common practice in the USA, especially at certain ports on the west coast where environmental awareness proves very high. There is also a technical benefit: freight and passenger ships use AC current at a frequency of 60Hz, the same as the American electrical mains network. Instead, the mains frequency in Europe is and always has been 50Hz, making cold ironing much more complicated, because expensive infrastructure is required and the change in frequency inevitably involves some loss. It should also be taken into account that, especially in Italy, energy is produced mainly at traditional thermal power plants whose electrical production efficiency ranges between 35% and 53% (depending on the plants modernity); said plants generate vast amounts of heat, dispersed into the environment (air and water) during combustion.
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For this reason, VTP Engineering has looked into alternative solutions compared to traditional Cold Ironing that uses the national mains.

Cruise ship/naval sector needs

Cruise ships require considerable amounts of energy ranging anywhere from 10 to 20 MW of power at 11,000 Volts. In Italy, the emissions of the industrial and energy sectors have been in decline for many years (decreasing by almost 50% between 1998 and 2006), but the amount of solphur oxide (SOx) generated by the maritime sector has practically doubled. National and international maritime traffic is responsible for more than 80% of total emissions attributable to transport and it is therefore one of the major sulphur oxide pollution sources on a global scale. This situation is obviously not sustainable in the long term, especially in Italy where many ports are situated near or even within towns historical centres. Cold ironing, therefore, offers a real possibility for protecting the environment and ensuring the health and wellbeing of citizens.

COLD IRONING IN COGENERATION

V.T.P Engineerings solution produces the power required for cold ironing directly at the port using a high efficiency generator that also exploits the heat generated during the power production process. This has been made possible by cogeneration technology, which ensures excellent yield (80%85%, compared to the 35-53% of energy generated by a thermal power plant), and optimal use of primary energy.

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Cogeneration also resolves the many problems associated with cold ironing using the national mains network. For instance, it: Resolves problems associated with frequency change (from 50 to 60 Hz), by using electrical engines connected to alternators. Minimizes loss due to transmission and distribution. Produces far less pollution than thermal power plants, as it uses 80-85% of the energy provided by the fuel (instead of 35-53%). Reduces the cost of energy (a return on investment within just a few years as any excess energy is sold to the national grid and the heat energy is used/sold). Generates environmental incentives such as green (GSE) certificates, energy efficiency awards, etc. Uses less space at the harbour than high/medium voltage transformer stations. Cogeneration in situ can be used as an alternative source of energy for ports and surrounding areas, even for emergency situations (and port security).

Electricity production: a comparison chart

Production of electricity at thermal power stations Production of electricity using cogeneration
For example, simple cycle internal combustion engines

35% (old plants) to 53% (new plants) electricity production

Approx. 46% electricity production Approx. 40% heat energy

HVSC power supply for stations and nearby areas, or transfer to the mains network

Teleheating/cooling for stations and nearby areas

65-47% energy loss,

into the air, rivers and sea

14% energy loss

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

Cogeneration with internal combustion engines

V.T.P Engineering, together with Rolls Royce, has devised a solution consisting of a cogeneration station that uses simple cycle internal combustion engines powered with bio-fuels or methane gas, and highly efficient environmental and noise pollution prevention systems. There are many benefits to this solution: Highly efficient production of electrical energy (44-46% yield), with simple cycle alone (not combined). Extreme flexibility and the possibility of frequent shutdown, as required for a Cold Ironing service, even in the case of ships with different and/or variable power requirements. Modular and compact structure (installation next to the required jetty, ensuring savings in terms of infrastructure). Excellent electrical yield when working at partial capacity (less than 5% loss of yield at 50% power). Production of hot and cold water for teleheating/telecooling.

Cogeneration energy using a gas-powered RollsRoyce Bergen engine

8.5 MWe
Methane gas 1850m3/h Electrical energy

8.44 MWt
Heat energy

Water at 48C 760 kW Water at 80C 990 kW Water at 89C 2158 kW Fumes at 415C 4530 kW 100-

Loss

1.41 MW
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AN EXAMPLE OF COLD IRONING FOR THE PORT AND TOWN

As an example, V.T.P Engineering, together with Rolls Royce, has analyzed the possible implementation of a cogeneration cold ironing system for the port of Venice. The solution is to install a cogeneration plant consisting of three internal combustion engines capable of producing the electrical energy required for two large cruise ships (max. electrical power supply is 24 MW). The heat produced, in the form of hot water, is used for the air-conditioning of port infrastructures and nearby urban areas. Teleheating produces hot water for heating (in the winter) and sanitary use (summer/winter) and further reduces pollution in the winter as the heaters in the buildings involved can be turned off. Moreover, absorption cooling units generate cold water at 7C for air-conditioning in the summer.

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

Using cogeneration technology for Cold Ironing at the port can also benefit the town itself as it: Reduces the pollution produced by traffic at the port. Provides clean electrical and heat energy. Reduces urban pollution due to use of heating systems during the cold season.

Therefore, the port can be seen, not only as an opportunity for boosting the towns economy, it can also be considered a resource for promoting sustainable development with respect for the environment.

The needs of the port and the historical centre of Venice

To better understand the importance of energy flow and the roles it plays, we can compare the key data of the port and the historical centre of Venice, associated with the energy produced by the cogeneration plant made up of three internal combustion engines. A few points concerning the cogeneration plant: The electrical and heat power produced far exceeds the amount required by port infrastructures. It makes sense, therefore, that the surplus energy is used in the urban area around the port. The electrical energy remaining after powering the ships with the cold ironing service, and the heat energy recovered, can satisfy much of the annual need generated in the historical centre of Venice. The use of heat energy can therefore greatly reduce atmospheric pollution.

PORT power requirement Heating at VTP terminals: Electrical power: 5.4 MW 4,0 MW

HISTORICAL CENTRE energy consumed / year (estimate) Domestic heating: Electrical energy for homes: 500,000 MWh 96,000 MWh

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The production of electrical and heat energy in 4,500 hours/year using the cogeneration plant
We can safely assume that the plant runs for at least 4,500 hours a year (the engines can run for more than 8,000 hours/year but the transfer of electrical and heat energy has to be certain).

ELECTRICAL ENERGY FOR SHIPS Electrical energy (supplied in 1,500 hours/year): 38,000 MWh

TELEHEATING/COOLING Heat energy/year: 103,000 MWh for use at the port and in the historical centre ELECTRICAL ENERGY FED INTO THE GRID Electrical energy/year: 76,000 MWh

The cogeneration Cold Ironing system is much more convenient the nearer the port is to the town. The cost of infrastructures for teleheating is minimized and the port becomes a primary source of power and a means for combating urban pollution.

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

Return on investment
The feasibility project naturally includes an economic analysis that takes into account the real situation of the installation and ends with an economic-financial plan concerning return on investment. Although there is no proper legislation in Italy that rewards proactive ventures such as this one, the plant would guarantee a return on investment within a reasonable amount of time. Said return could be further improved by increasing annual operating hours and by using bio-fuels (at current prices, and with strongly incentivizing state policies). Other forms of cold ironing can only put up investment with margins on selling energy to ships, or with other incentives.

The table below gives an idea of unit costs and possible income.

INITIAL INVESTMENT: 15,000,000 - 24,000,000

( 600,000 1,000,000 /MWe installed)

Figures for 4,500 hours/year using gas engines ANNUAL COSTS ANNUAL INCOME

Supply of methane gas 6,300,000

Electrical energy supplied to ships

average price 60/MWeh

2,280,000

Running costs (5 employees)

250,000

Electrical energy fed into the grid

average price 60/MWeh

4,560,000

Maintenance 1112/MWeh

1,300,000

Energy produced for heating systems

average price 70/MWth

4,000,000

Lubricating oil

130,000

Energy produced for cooling systems

average price 20/MWth

550,000

TOTAL ANNUAL COSTS

7,980,000

TOTAL ANNUAL INCOME

11,390,000

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

Examples of Rolls - Royce applications

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

Rolls - Royce systems (Gas Turbine & Engine Bergen): TELEHEATING in Italy
15 teleheating plants with 35 engines and 4 Turbogas turbines Between 2MWe and 80MWe Approx. 80% total efficiency Annual operation: 3,500 6,000 hours High energy efficiency even without heat recovery

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

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Study of 3x8.5MWe CHP Passenger Terminal, Venice

Optional 4engine

V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

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V.T.P. Engineering Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it www.vtpengineering.it

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