E-PowerPack | Alfa Laval

The Alfa Laval E-PowerPack

The Alfa Laval E-PowerPack converts waste heat directly into clean electrical power, giving marine vessels a plug-and-play efficiency upgrade for meeting sustainability requirements. Based on Organic Rankine Cycle (ORC) technology, this compact and easily installed module can make use of a wide variety of gas and liquid heat sources on board. It thus provides an all-in-one solution that lowers fuel costs, reduces emissions and shrinks carbon footprint.

E PowerPack

Power your way to energy savings and compliance

 

  • Convert onboard waste heat directly into electrical power
  • Increase fuel efficiency
  • Reduce emissions and carbon footprint
  • Improve Energy Efficiency Index (EEDI/EEXI)
  • Improve Carbon Intensity Indicator (CII)

 

The E-PowerPack is a game-changing advance in marine sustainability. It turns waste heat into freely available power, generating electricity from both high-temperature and low-temperature sources. Heat in the engine exhaust gas accounts for 50% of the energy from combusted fuel, and further energy can be recovered from sources like jacket cooling water – or the excess steam resulting from the switch to low-sulphur fuel.

By reducing fuel consumption, emissions and carbon footprint, the E-PowerPack provides a cost-saving tool for meeting sustainability requirements. No matter which fuel is used, it improves both EEDI/EEXI and CII. This enables vessels to achieve the necessary index and maintain a favourable rating for longer.

Compact and modular, E-PowerPack units with a net electrical output of up to 100 kW or 200 kW can be combined in a larger system.

Documents

Services

Start-up

  • Installation supervision
  • Commissioning

Maintenance

  • Spare Parts

Support

  • Troubleshooting

24/7 Service & Support

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Contact us anywhere, anytime:

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+46 4636 7700

E-mail: marine.service@alfalaval.com

How it works

The E-PowerPack generates electricity by means of an Organic Rankine Cycle (ORC), a closed thermodynamic system where the liquid-vapour phase change of an organic refrigerant is used to drive a generator. High-temperature waste heat is fed into the E-PowerPack by means of a heat exchanger and an intermediate hot water loop, whereas low-temperature fluids are fed into the unit directly.

Within the E-PowerPack, a continuous process occurs:

  • The heat evaporates the liquid refrigerant, producing superheated vapour that passes into an expander
  • The vapour’s expansion turns rotary screws that drive the unit’s generator, producing electricity
  • The refrigerant is reliquefied in a condenser and repressurized by the feed pump, allowing the cycle to begin again

Potential heat sources

  • Exhaust gas (max. 550°C)
  • Saturated steam (120–180°C)
  • Thermal oil (120­–180°C)
  • Jacket cooling water (75–109°C)

 

Savings with the E-PowerPack

The following example shows how much the E-PowerPack can save on a given vessel. Reduced fuel costs enable payback and profit in just 2­­­–3 years.

Conditions

  • Steam surplus: 2300 kg/h
  • Avg. power output: 150 kW
  • Operating hours per year: 7200
  • Annual power output: 1080 MWh

Annual savings and payback time

 

VLSFO ($530/tonne)

  • Cost savings: $115,000 per year at $0.10/kWh
  • CO2 savings: 670 tonnes
  • Payback: 2.9 years

 

LNG ($800/tonne)

  • Cost savings: $138,000 per year at $0.13/kWh
  • CO2 savings: 475 tonnes
  • Payback: 2.4 years

 

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Supporting the transition to zero carbon

The E-PowerPack can be used on any vessel and with any fuel. As the marine industry decarbonizes, it will be instrumental in the move to methanol – and later to ammonia. These fuels are less energy-rich than today’s fuels, so vessels will need to maximize the value from the fuel they carry. Alongside other Alfa Laval solutions, the E-PowerPack will be critical to the energy balance.

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