Developing a digital twin for the ammonia fuelling system structure: A systems approach

<ns3:p>Waterborne transport accounts for approximately 25% of the European Union’s greenhouse gas (GHG) emissions, a share expected to grow with increasing global trade. To meet the EU’s goal of a 90% reduction in GHG emissions by 2050, alternative fuels and innovative technologies are essential. Ammonia (NH<ns3:sub>3</ns3:sub>) has emerged as a promising zero-carbon fuel; however, it requires nearly three times the storage volume of conventional fuel oil. The NH3CRAFT project addresses this challenge by aiming to design and demonstrate safe, sustainable large-scale NH<ns3:sub>3</ns3:sub> storage—1,000 m<ns3:sup>3</ns3:sup> at 10 bar—aboard a 31,000 Deadweight tonnage (DWT) vessel. The project employs a digital platform that integrates computational models, simulations, and real-time sensor data—including AI-enabled inspections—to support the development of a Digital Twin (DT). While DTs are well-established in the automotive and aerospace industries, their use in maritime applications is evolving, especially in the areas of structural health monitoring (SHM) and predictive maintenance. This study applies a systems engineering approach from an SHM specialist’s perspective to assess the feasibility of implementing a DT specifically for the NH<ns3:sub>3</ns3:sub> fuelling system. Key technical gaps and system-level considerations for NH<ns3:sub>3</ns3:sub>-specific SHM integration into the DT were identified through collaboration with project partners. These include challenges in sensor deployment, data fusion, and the need for high-fidelity modelling of NH<ns3:sub>3</ns3:sub> behaviour under dynamic maritime conditions. The study outlines requirements for building a hard system capable of ensuring long-term structural integrity and safety. The development of a DT for the NH<ns3:sub>3</ns3:sub> fuelling system presents significant potential to enhance SHM and operational safety. A strategic decision remains pending within the consortium regarding the full-scale implementation of the DT. This study provides a foundational framework to support that decision and future DT development in maritime NH<ns3:sub>3</ns3:sub> applications.</ns3:p>