V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

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COLD IRONING

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“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 ship’s 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 plant’s modernity); said plants generate vast amounts of heat, dispersed

into the environment (air and water) during combustion.

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

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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 Engineering’s 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.

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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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).

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

65-47% energy loss,into the air, rivers and sea

Production of electricity at

thermal power stations

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

Teleheating/cooling for stations and nearby areas

EElleeccttrriicciittyy pprroodduuccttiioonn:: aa ccoommppaarriissoonn cchhaarrtt

14% energy loss

Approx. 46% electricity production

Approx. 40% heat energy

PPrroodduuccttiioonn ooff eelleeccttrriicciittyy uussiinngg ccooggeenneerraattiioonn

For example, simple cycle internal combustion

engines

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

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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.

CCooggeenneerraattiioonn eenneerrggyy uussiinngg aa ggaass--ppoowweerreedd RRoollllss--RRooyyccee BBeerrggeenn eennggiinnee

8.5 MWe

Methane gas

1850m3/h

8.44 MWtWater at 48°C 760 kW

Water at 80°C 990 kW

Water at 89°C 2158 kW

Fumes at 100°-415°C 4530 kW

Electrical energy

Heat energy

Loss

1.41 MW

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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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 7°C for air-conditioning in the summer.

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

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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 town’s 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.

HISTORICAL CENTRE energy consumed / year (estimate)

• Domestic heating: 500,000 MWh • Electrical energy for homes: 96,000 MWh

PORT power requirement

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

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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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”).

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.

TELEHEATING/COOLING • Heat energy/year: 103,000 MWh

for use at the port and in the historical centre

ELECTRICAL ENERGY FOR SHIPS

• Electrical energy (supplied in 1,500 hours/year): 38,000 MWh

ELECTRICAL ENERGY FED INTO THE GRID

• Electrical energy/year: 76,000 MWh

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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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.

ANNUAL INCOME ANNUAL COSTS

• Supply of methane gas € 6,300,000 • Running costs € 250,000

(5 employees) • Maintenance € 1,300,000

€ 11÷12/MWe·h • Lubricating oil € 130,000

• Electrical energy supplied € 2,280,000 to ships average price € 60/MWe·h

• Electrical energy € 4,560,000

fed into the grid average price € 60/MWe·h

• Energy produced € 4,000,000

for heating systems average price € 70/MWt·h

• Energy produced € 550,000

for cooling systems average price € 20/MWt·h

Figures for 4,500 hours/year using gas engines

INITIAL INVESTMENT: € 15,000,000 - € 24,000,000 (€ 600,000 ÷ 1,000,000 /MWe installed)

TOTAL ANNUAL INCOME € 11,390,000 TOTAL ANNUAL COSTS € 7,980,000

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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Examples of Rolls - Royce applications

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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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

11

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

Optional 4°engine

V.T.P. Engineering

Tel e fax +39 041 2403051 vtpengineering@vtpengineering.it

www.vtpengineering.it

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