ENERGY SHIFT TO TRANSFORM SHIPYARDS, AS WELL AS SHIPS

Shipping’s appetite for “future-proof” vessels capable of using alternative fuels or energy sources was once again demonstrated by the latest update from Clarksons Research’ Green Technology Tracker. Full-year data for 2023 shows that 539 newbuild orders that year, representing 45% of all orders placed by tonnage, were for alternative-fuel capable designs.

The report also shows a significant expansion in the use of energy saving technologies, including propeller ducts, rudder bulbs, air lubrication and wind propulsion systems, which have so far been fitted to more than 7000 vessels in the global fleet, accounting for 29.5% of the total tonnage.

New fuels, new design challenges

For naval architects and engineers in charge of creating those ships, the growing focus on new fuels and power systems has a direct consequence: it increases the complexity of designs. The single fuel era is over. Going forward, ships will be powered by a broader range of fuels, technologies, and alternative energy sources – all of which have their own specifications and implications for the vessel’s structure, stability profile, safety requirements and general arrangement.

For example, using hydrogen as a fuel will require at least twice as much storage space compared to conventional fuel oil, depending on the technology selected. Similarly, propelling a ship with ammonia will necessitate the installation of additional fuel tanks and safety systems to prevent and detect leaks. Due to the flammability or toxicity of some fuel options, specific configurations may be needed to ensure that tanks are isolated from living quarters or any sources of heat, or to incorporate additional ventilation systems, for instance.

Beyond fuels, other green technologies also have major implications for design. Lithium batteries are twice as heavy as their fossil fuel equivalent, which may bring the ship closer to its maximum load mark and needs to be accounted for at the design stage. Therefore, creating “future-proof” ships is a lot more complex than simply installing a different engine or power source – it often involves rethinking the entire design to ensure the ship’s safety, stability and performance.

Efficiency as a prerequisite for innovation

For shipyards, the decarbonisation transition is a challenge as much as it is an opportunity. The Japan Shipbuilder’s Association forecasts that the energy transition will drive a rapid expansion of the shipbuilding market in the next decade, which is expected to surpass historical peaks. Meanwhile, in late 2023, South Korea has launched a new strategy, including a $547m investment, to reinforce its positioning in the “next gen” shipbuilding market.

But success in the multi-fuel era will depend on the capacity to manage the inevitable complexity of new designs, while respecting increasingly challenging time constraints. This calls for a new ship design approach which supports effective multidisciplinary design and concurrent engineering, collaboration and transparency among stakeholders, and emphasises simulation.

Designing a ship is inherently an iterative process that typically involves several teams in charge of structures, propulsion, electrical, general arrangements, and weight estimations, for example. To innovate, they need an efficient integrated engineering experience that offers the flexibility to make swift design changes and ensures that everyone involved is on the same page.

A key place to start is by making greater use of 3D models throughout the design process, from the early stages through to classification approvals, detail design, and all the way in downstream production design, eventually also serving as an asset for life-cycle maintenance in the form of digital twins. This helps break siloes between disciplines, enabling teams to communicate efficiently while also eliminating duplicate work and limiting the risk of errors.

In addition to using 3D tools to streamline processes, the next frontier will be to make the most of their potential to support decision-making. 3D models unlock the possibility to use next-generation simulation tools to test different fuel and technology options, and model their implications for the ship’s configuration, cargo capacity, stability, and even its future performance on different routes.

In short, naval architects and engineers will be able to compare different alternatives from the outset to deliver the best possible concepts for their clients. This is a game-changer and an essential asset for the multi-fuel and multi-technology era ahead, giving shipowners more certainty about how their newbuilds will perform in real life. Naval architects and engineers today are designing ships that will navigate in a very different commercial and technology landscape. While they are designing for the unknown, they can be certain of one thing: by building today the digital foundations for an efficient and collaborative design process, they can make sure they are set up to thrive.