LPG for Marine Engines The Marine Alternative Fuel Commercial, Passenger, Offshore Boats/Ships, Recreational Crafts and Other Boats Innovation & Technology The World LPG Association The WLPGA was established in 1987 in Dublin, Ireland, under the initial name of The World LPG Forum. It unites the broad interests of the vast worldwide LPG industry in one organisation. It was granted Category II Consultative Status with the United Nations Economic and Social Council in 1989. The WLPGA exists to provide representation of LPG use through leadership of the industry worldwide. Forward A great man once said “To know something and not do it is the same as not knowing it at all”. What we take for granted today was impossible just a few years ago. The quick adaptation of LPG as a fuel in the marine sector would be a great step forward for the environment, cleaner air and cleaner water. With its lower cost of implementation and its readily available infrastructure, LPG, an exceptional energy, has significant advantages over other alternative fuels. As a pioneer in LPG marine applications, I see as my maritime mission to assist in the rapid adaptation of this exceptional solution changing the world for the better. I believe this report, thanks to the World LPG Association, creates that ripple in the water that can carry across the oceans. Capt. Bernardo Herzer, chair of the WLPGA Marine Group. Acknowledgements This report has been developed by the Innovation & Technology Network of WLPGA. There could be views expressed in this document that are not necessarily shared by all contributors. Key contributors: George Nikolaou, Natco/AEGPL Bernardo Herzer, LEHR, Chair of the WLPGA Marine Group Cameron Ure, Elgas David Tyler, WLPGA Makoto Arahata, Japan LPG Association Niels Frederiksen, Hexagon Ragasco Peter Hadjipateras, Dorian LPG Øyvind Solem, BW LPG Rubens Basaglia, X-Tech Tatsuya Hamaguchi, Astomos Tucker Perkins, PERC Warring Neilsen, Elgas Nikos Xydas from WLPGA coordinated this project. Page 1 LPG for Marine Engines, The Marine Alternative Fuel LPG for Marine Engines The Marine Alternative Fuel Commercial, Passenger, Offshore Vessels, Recreational Crafts and Other Boats Contents Page Chapter One Introduction 6 Chapter Two Executive Summary 7 2.1 Key Messages – Fact Sheet 8 2.2 Key Messages – Roadmap 12 2.3 Key Messages – Recommendations 13 Chapter Three Fact Sheet 14 3.1 The Product - LPG as Marine Engine Fuel 14 3.1.1 Supply and availability 15 3.1.2 Pricing 16 3.1.3 Environmental, Emissions to air and water 16 3.2 Marine Engine Technologies 18 3.2.1 High Speed LPG Fuelled Engines (>1000rpm) 19 3.2.2 Medium Speed LPG Fuelled Engines (300-1000rpm) 21 3.2.3 Low Speed Engines (<300rpm) 23 3.2.4 Electric Motors (with LPG generators) 26 3.2.5 LPG range extenders 28 3.3 Marine LPG engine types 29 3.3.1 Otto petrol/LPG Bi-Fuel engine 30 3.3.2 Otto LPG Mono Fuel engine 30 3.3.3 Dual-Fuel Diesel/LPG (Diesel engine with LPG injection) 30 3.3.4 Diesel-Ignited LPG engine 33 3.3.5 Gas Fuel or Tri Fuel Propulsion 33 3.3.6 LPG Gas Turbine 34 3.3.7 LPG Outboard engine, Mono Fuel or Bi-Fuel 36 3.4 Boat/Ship propulsion 38 3.4.1 Direct drive 39 3.4.2 Hybrid, Parallel 40 3.4.3 Hybrid, Serial 44 3.4.4 Electric with “Range Extender” engine 46 3.4.5 Tri Fuel Propulsion 47 3.4.6 Outboard/Inboard engine 48 3.4.7 Ethane powered ship engine 50 3.5 Marine Engine Application Segments 52 3.5.1 Boat/Ship Segments Overview 52 3.5.2 Commercial Boats/Ships 53 Page 3 LPG for Marine Engines, The Marine Alternative Fuel 3.5.2.1 Cargo ships 53 3.5.2.1.1 Large ocean-going ships - VLGCs 53 3.5.2.1.2 Tankers 57 3.5.2.1.3 Bulk 57 3.5.2.1.4 Containerships 59 3.5.3 Fishing Boat/Ships 61 3.5.4 Passenger Vessels 62 3.5.4.1 Cruise ships 62 3.5.4.2 Ferries 63 3.5.4.3 Yachts 66 3.5.5 Offshore Service Boats 67 3.5.5.1 Exploration and Production 67 3.5.5.1.1 Seismic Vessel 67 3.5.5.1.2 Drill Ship 67 3.5.5.1.3 Cable/Pipe Layers 68 3.5.5.2 Towboats 68 3.5.5.3 Supply + Service Boats 68 3.5.5.3.1 Platform Supply Vessels 68 3.5.5.3.2 Anchor Handling Vessels 69 3.5.5.3.3 Safety Standby Vessels 69 3.5.5.3.4 Installation Vessels 69 3.5.6 Recreational Crafts and Other Boats 70 3.5.6.1 Rib and Speed Boats 71 3.5.6.2 House Boats 73 3.5.7 Naval Vessels 74 3.5.7.1 Military 74 3.5.7.2 Rescue/Patrol 74 3.5.8 Others 75 3.5.8.1 Dredgers 75 3.5.8.2 Tugs- Work Boats 76 3.5.8.3 Ice Breakers 76 3.6 Conversions and Retrofitting 77 3.7 LPG vs LNG and CNG 78 3.8 Logistics and fuel storage infrastructure 88 3.9 Main Players 90 3.10 Regulatory Framework in the Marine Sector 91 3.10.1 Regulatory Framework in Recreational Craft sector 91 3.10.2 Regulatory Framework in Commercial and Shipping sector 92 3.11 Safety 98 3.12 Training 100 3.13 Quality of Fuel 101 3.14 Environmental aspects 102 LPG for Marine Engines, The Marine Alternative Fuel Page 4 3.15 Main stakeholders 105 3.15.1 Design offices 105 3.15.2 Marine engine manufacturers 107 3.15.3 Shipyards 109 3.15.4 Classification Societies 109 3.15.5 Ship owners, Cargo owners, Ship operators 109 3.15.6 LPG distribution companies, Associations 111 3.15.7 Policy makers, Governments, Regulators 111 3.15.8 Other Societies 111 3.16 Engagement of Stakeholders 112 3.17 Market Status 113 Chapter Four Roadmap 114 4.1 Market Outlook Technology Developments 114 4.2 Market Outlook on Regions 116 4.3 Barriers to Market Growth 117 4.3.1 Customer Economics 117 4.3.2 Positioning LPG to policymakers and decision makers 118 4.3.3 Technology Development of new engines 118 4.3.4 Commercialisation of new engines 119 4.3.5 LPG Awareness/Perception for decision makers 119 4.3.6 Bunkering Infrastructure 119 4.4 Market Potential 121 4.4.1 Target Market Regions 122 4.4.2 Target Boat/Ship Segments 124 Chapter Five Recommendations 126 5.1 Customer Economics 127 5.2 Positioning LPG to policymakers and decision makers 127 5.3 Technology Development of new engines 127 5.4 Commercialisation & Getting Products to Market 128 5.5 LPG Awareness/Perception for decision makers 128 5.6 Bunkering Infrastructure 129 Appendices Appendix 1 Financial analysis of retrofit options of an existing 38,500 TDW tanker vessel 130 Appendix 2 Hybrid propulsion packages 134 Appendix 3 LNG vessels order book 136 Abbreviations 139 References 140 Page 5 LPG for Marine Engines, The Marine Alternative Fuel Chapter One Introduction The aim of this report is to promote understanding amongst the LPG industry and beyond, of the technical possibilities, applications and market potential of LPG for Marine engines. Ultimately this is to inform the LPG community of the numerous opportunities in the various related segments, of current development in the gaseous fuel market and of actions to take, in order to “pave the way” for take-up in the marine routes. The report scope includes:  A scan of the market for Marine LPG engines and even more in this case for Marine engines and particularly those Gas Marine engines, which after additional development or conversion could use LPG as a fuel. This scan covers primarily Europe, US, Asia, Japan and some highlights from other parts of the world.  Identification of market characteristics and marine engine applications which are more promising for LPG as Marine fuel.  Coverage of commercial and passenger vessels as well as emerging developments in inboards, outboards recreational boats and other crafts. The main objective is besides giving a bird-eye’s view snapshot of the sector as a whole, to identify concrete opportunities for the LPG industry. This report contains:  A ‘fact sheet’ giving an overview of the current marine LPG and other gaseous fuel technologies, main players in the value chain and market status.  A ‘roadmap’ providing stakeholders with different types of boat propulsion systems, exploring the market outlook for each technology and identifying the drivers and barriers for future growth.  Recommendations targeting stakeholders and association members on how to overcome the barriers for entering the shipping sector and also on maximising the market opportunity in existing smaller waterborne vessels. LPG for Marine Engines, The Marine Alternative Fuel Page 6 Chapter Two Executive Summary Global marine propulsion engine revenue market is expected to reach $12 billion by 2022, growing yearly at around 4.1% from 2016 to 20221 and it is expected to witness robust growth during the forecast period owing to various ongoing government investments in shipbuilding industry and inland waterways. Diesel marine propulsion engines (including scrubbers) have led the overall market, accounting for 70% in 2015. The increase in production and sales of ships globally and the rise in international seaborne trade, partly also due to increase in demand for resources such as crude oil, coal, steel, and iron from developing countries, drive the market growth. Over 90% of the world’s goods by weight and volume are transported by sea. Offshore exploration and production is expected to grow to 45% from 35%, over the next decade.2 However, stringent environmental regulations and large capital investment required to set up new manufacturing facilities hamper the market growth. Irrespective of these challenges, rise in usage of inland waterways and advancements in technologies, such as new alternative fuel propulsion engine technologies, are expected to provide various opportunities for these technologies and boost market growth. The use of LPG as an engine fuel is the most commonly accepted alternative fuel in the world today. Despite this, LPG has not made its entry yet at any significant level into the marine market segment. LPG as propulsion fuel is today almost absent from the shipping sector and especially from commercial vessels, where the vast majority of engines are diesel, and alternative fuels solutions as LNG and CNG continue their growth. In smaller commercial and recreational vessels with inboard and outboard engines, LPG has been also little exploited up to now, although there are some areas/countries where it has indeed been used. However, regarding larger commercial and passenger ships, and in light of the 2020 IMO mandate, LPG is starting to get some attention as it stands as a likely alternative amongst the other gaseous fuels. Ship operators, with traditional propulsion plants and fuels, cannot meet the new 2020 regulations without installing expensive exhaust after- treatment equipment or switching to low‐sulphur diesel, low‐sulphur residual, or other alternative fuels, all of which impact bottom‐line profits. As attention turns to an array of possible solutions, heavy-sulphur fuel oil with scrubbers, distillates, blended fuels and LNG, to comply with the IMO's 0.5% global sulphur cap regulation, LPG may gain more acceptance as a viable solution, as compared to LNG, which in reality, is more problematic and expensive to implement. LPG supply surplus is another element in favour, with surpluses ranging from 15 to 27 million tonnes per year2, which are either used or “lost”. The dropped prices of LPG (comparatively also with LNG) driven by the shale gas revolution are also an important driver for market entry. Shipbuilders are already considering vessel designs that use LPG as propulsion fuel. There is no reason why LPG cannot be used in all sizes of vessels from the largest of ocean going ships, down to the smaller boats with inboard or outboard engines. LPG can play a major role in this changing environment and re-establish itself in the position that it deserves as an ideal alternative clean marine fuel. Coordinated action from all related stakeholders is key to address the identified specific issues that hinder development and release the market potential. Page 7 LPG for Marine Engines, The Marine Alternative Fuel 2.1. Key Messages - Fact Sheet LPG when used as an engine fuel has numerous advantages and a largely untapped potential for marine engines.  The use of LPG as an engine fuel is one of the largest and fastest ones growing globally. The properties of LPG and namely its low emissions and its virtually zero particulate emissions, can have an immediate positive impact on air quality.  LPG is a viable alternative gaseous fuel and it can be very much so, as a marine fuel for all sizes and types of boats and ships. It is true that the alternative fuels industry has grown dramatically for both liquid and gaseous fuels, but for LPG, although it is relatively easier and more economical to set it up on a vessel compared to LNG, the push remains still limited so far. Only recently, the shipping industry and more particularly the bunkering sector is considering a bigger role for LPG as a shipping fuel for the years to come.  The bunkering infrastructure for natural gas is not mature, whereas for LPG there is already considerable existing infrastructure available around the world that can be used, storage facilities, export terminals, coastal refineries with loading/unloading facilities etc.  For LPG carriers, there are even more benefits to use LPG as fuel and in doing so save bunkering time.  Some ship owners and manufacturers seem to be getting ready to embrace LPG, and especially so with LPG prices being very attractive. The marine propulsion engine market is expected to witness robust growth during the forecast period owing to various ongoing government investments and new regulations in shipbuilding industry and inland waterways.  It is true that the availability of large LPG fuelled engines is very limited today. However, variants of large engines and propulsion configurations fuelled by natural gas have been developed, which makes eases the way for further development of such engines to run on LPG.  Due to advancement in technology, diesel or alternative fuel engines and gas turbines have attained greater market penetration.  Small inboard and outboard engines are almost exclusively targets for LPG, either as conversions similar to Autogas vehicles, or as OEM models as those of LEHR and recently also of Tohatsu.  Electric hybrids as a marine propulsion technology, have been used for many years, and recently have seen their growth as a solution to improve efficiency, reliability and modulability of the whole powertrain systems of most types of ships, boats. The Marine engines and propulsion system technologies segment can be divided into petrol, diesel, LPG, LNG, and other propulsion system technologies as gas and steam turbines, hybrids etc.. In summary, a categorisation of engines that can use LPG as a fuel, could be as below:  Spark-ignited “Petrol-LPG bi-fuel or LPG only” engines, first developed for the land-based power industry with simplicity and good overall performance at lowest total emissions as prime requirements. They initially came into the marine industry as engines for outboard and inboard engines.  Diesel gas engines with direct LPG injection first appeared in the offshore industry where fuel flexibility and very high-power density was of prime attraction. A concept unique in posing no particular requirements to the self- ignition stability of the fuel gas and its diesel operating principle ensuring very complete combustion of the gas fuel but at the cost of higher NOx emissions than other gas engine types. Its use in marine industry is limited.  Diesel-ignited LPG engines with dual fuel capability originally developed for power plant use where their ability to operate both on liquid and gaseous fuels at high specific power was a particular advantage. They burn LPG and use marine diesel oil as pilot fuel. This is the most promising market, capable of operation on gas and/or GFO, in different applications such as container ships, bulk carriers, ConRo vessels, and LPG carriers. Development focus LPG for Marine Engines, The Marine Alternative Fuel Page 8 was originally on low NOx emissions at high loads, recently also on part load performance and variable speed capability. The diesel-ignited gas/LPG engine was the first type to establish itself in the marine industry and is currently the dominating engine type in this market.  Gas turbines (could run on LPG), conventional gas turbines combined with power generator turbines to provide power to the ships propeller, a system of ship propulsion known as “split-shaft gas turbine”. The gas turbine drive shaft contains the turbine starter, while the auxiliary pumps drive the different systems. The gas turbine hot exhaust gasses are fed into the power generator turbine. Gas turbine advantages are power density (i.e., high power in a light weight, small footprint), fuel flexibility and highly reliable Dry Low NOx emissions combustion system. They also provide superior availability for diverse military applications, ranging from patrol boats, corvettes, frigates, destroyers and cruisers. Other potential applications include hydrofoils, fast ferries, cruise ships, floating production storage and offloading vessels, offshore platforms, power barges, high-speed yachts and LPG carriers.  Outboard engines “Bi-fuel or LPG only” have become a marine propulsion alternative in protected lakes and rivers, as well as fish farms, as a replacement of gasoline two and four stroke polluting engines from their exhaust, not to mention also spillages during refuelling, of detrimental effect on the water and aquatic wildlife. In addition, there are also noteworthy running cost benefits. The restrictions on the use of internal combustion engines on many protected areas leave LPG fuelled outboard and inboard engines as the prime alternative. The Marine engine applications and vessel types market could be categorized as follows: Large commercial ships, cargo ships, large ocean-going ships, VLGCs, tankers, bulk carriers, containerships, passenger ships of all types, offshore service vessels, towboats, dredgers, house boats, recreational craft, even military vessels, patrol and rescue boats and many more can be a target for use of LPG with varying attractiveness for each type, benefits and priority. LPG can compete economically with LNG and probably also with low sulphur fuel oil after the global sulphur cap changes to 0.5% for new builds.  Retrofits will be less cost efficient than new builds.  The current global production of LPG and its future increase opens up possibilities for LPG as a marine fuel.  The spatial distribution of LPG storage facilities favours LPG over LNG, since the development of a bunkering infrastructure remains a barrier.  Market introduction for a non-drop-in fuel, such as LPG, will always be a challenge, but easiest implementation could be in LPG VLGCs, where fuel is already present (or can be bunkered in connection to cargo loading), and where handling of LPG is well known and safely managed, thereby reducing the distribution costs.  LPG has the advantage of more economical implementation and largely available and less costly infrastructure, terminals, supply points. This is particularly important in certain sectors including small tankers, smaller container vessels and ro-ro ships that operate in coastal areas and on inland waterways where LPG supply infrastructure is always in proximity. Safety issues linked to the use of LPG as a marine fuel must be addressed, but these are no more challenging than for LNG.
New technologies as those related to the use of LPG as marine fuel, as well as the use of LPG as a product itself, require competent operators hence adequate training.  Training in the specific installation and the handling of the product itself should always be part of any new project. Page 9 LPG for Marine Engines, The Marine Alternative Fuel