UK companies Archipelago Yachts and Chartwell Marine have completed a demonstration of a methanol-powered range extension system designed for electric vessels. According to the two firms, the system delivers an effective energy density approximately 10-12 times greater than current marine lithium iron phosphate batteries.
The demonstration was carried out as part of the Innovate UK-funded Methanol Pathfinder UK project, supported through the UK government’s Clean Maritime Demonstration Competition (CMDC6) and UK Shipping Office for Reducing Emissions (Shore) programme.
The prototype – developed and tested at Archipelago Yachts’ Isle of Wight facility – converts methanol into hydrogen, then generates electricity via a fuel cell. This system is intended to extend the operating range of electric vessels without relying on combustion engines.
Testing showed that the complete energy conversion process achieved efficiency comparable to that of marine diesel engines. The effective gravimetric energy density of the consumed methanol was measured at approximately 1.5kWh/kg.
The project addresses one of the practical barriers to wider adoption of electric propulsion in the marine sector. While battery-electric vessels are becoming more common on shorter routes, the lower energy density of batteries can restrict their use on longer passages, commercial operations and offshore applications. The project examined methanol as a liquid fuel that could extend operating range while maintaining near-zero emissions when produced from sustainable sources.
Stephen Weatherley, CEO of Archipelago Yachts, says: “The results exceeded our expectations and provide real-world validation of a technology that could fundamentally change how electric vessels are powered. We have demonstrated that methanol can be converted into usable electrical energy with sufficient efficiency to make it a viable range-extending solution for vessels that would otherwise be constrained by battery capacity. Achieving an effective energy density 12 times greater than marine batteries is a significant milestone for the industry.”
The prototype combines commercially available components, including an E1 Marine methanol reformer, an Auriga Energy hydrogen fuel cell, a 100kW electric propulsion system and a 100kWh high-voltage battery installation.
The equipment was housed within a modified 20ft container, allowing the project team to carry out testing and gather performance data under representative operating conditions.
The work also increased the system’s estimated Technology Readiness Level (TRL) from 2-3 to 5-6, moving it from an early concept to an integrated prototype that has been tested.
Environmental analysis carried out during the project indicated that, when using green methanol, the system produces near-zero lifecycle carbon emissions while substantially reducing NOx, SOx and particulate matter compared with conventional marine diesel engines.
The analysis further estimated emissions reductions of around 40 tonnes of CO2 per vessel each year in leisure applications, with larger savings possible in commercial sectors including offshore wind support vessels and crew transfer vessels.
Andy Page, managing director of Chartwell Marine, says: “One of the most important outcomes is that we’ve generated hard performance data rather than theoretical projections. The technology has now been physically built, integrated and proven.”
“The results demonstrate that methanol offers a realistic pathway to overcoming the range limitations currently facing electric vessels. That opens up significant opportunities across the leisure, commercial and offshore sectors.”.
The companies say the project has already attracted commercial interest, with discussions underway about establishing a dedicated business to bring the technology to market. The consortium also says it has identified a potential customer interested in integrating the system into an all-electric Archipelago vessel.
Archipelago Yachts and Chartwell Marine are now considering the next phase of development, which could include a sea-going demonstrator vessel and further funding applications to support commercial deployment.
According to the consortium, the technology could be suitable for explorer yachts, pilot boats, offshore wind support vessels and other vessel types where battery-only propulsion remains less practical.
Archipelago Yachts is a UK builder specialising in aluminium explorer yachts. The company develops vessels with a focus on long-range capability and sustainable propulsion technologies.
Chartwell Marine is a UK naval architecture and vessel design company. It provides design and consultancy services across commercial, offshore wind, passenger and leisure marine sectors.
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