From readiness to reality: Helping power the methanol transition

Authors: Jeppe Jacobsen, Head of Global Sales, Heat & Gas Systems, Alfa Laval, and Stefano Bottino, Global Sales Manager, Fuel Supply Systems, Water, Wind and Fuel Solutions, Alfa Laval

Alfa Laval is taking a pivotal role in driving the industry’s transition with our methanol-capable solutions. The successful commissioning of our fuel supply systems and methanol-ready boiler systems showcases our ability to deliver innovative solutions that support shipowners in their decarbonization journey." - Jeppe Jacobsen

There is a reason behind the success of FCM Methanol. Every retrofit or newbuild we support begins with close dialogue with the customer. It’s not about selling a product, it’s about understanding how to optimize product configuration for the best project fit, class requirements and long-term fuel strategy. Methanol isn’t a drop-in fuel; it changes the rules. Our job is to turn that complexity into an efficient and safe solution – together with the shipowner, designer and yard." - Stefano Bottino

Ten years ago, if you’d asked most people in the marine industry whether methanol would play a major role in shipping’s decarbonization journey, you’d likely have seen a lot of raised eyebrows. Back then, methanol was still considered a niche alternative. However, at Alfa Laval, we’ve always tended to look a little further ahead. Fast forward to today and what once seemed like an energy curiosity has become an everyday reality.The methanol transition is happening fast and at Alfa Laval we’re not just part of it, we’re helping to lead it.

Imagining the future, engineering the present

Methanol has become one of the most promising candidates for reducing emissions from shipping operations. When sourced renewably (green methanol), it can slash CO₂ emissions by up to 95%. Liquid at ambient conditions, it is easier to handle than some alternative fuels such as ammonia. While global methanol production is well established, primarily serving the chemicals industry, the transition to green methanol is still ramping up. Near-term availability is expected to meet initial shipping demand, supported by existing bunkering infrastructure that is mature and relatively straightforward to scale. As green production capacity grows – particularly in Asia and Europe - methanol’s role in the fuel transition is set to expand significantly.The recent developments around ethanol can further facilitate the transition to green methanol. Ethanol is widely available in major trading regions such as Brazil, the USA, EU, China and India; sourced exclusively from renewable and food-industry byproducts. With similar chemical properties and higher energy density than methanol, ethanol offers advantages in onboard storage and ease of integration for engine manufacturers. FCM Methanol is already capable of handling ethanol with only minor adjustments.But the real question is: how do you take a promising idea and make it work – reliably, safely and at scale – in the demanding world of shipping? That’s the space where Alfa Laval thrives.

Pioneers since 2015

We’ve been working with methanol since 2015 - not just in theory, but through ongoing operation on vessels across the globe. Over the years, our systems have been tested with all the types and brands of engine, and installed onboard all types of cargo vessels, giving us a practical understanding of methanol’s behaviour under real conditions.That knowledge has guided the development of our solutions. We’ve seen first-hand how methanol responds to shifts in load, climate and fuel demands, and we’ve used those insights to refine our approach.The result is our FCM Methanol low-flashpoint fuel supply system (LFSS) which has now reached its fourth generation and is significantly ahead of our competitors. It's been chosen for more than 170 vessels and by over 25 shipping companies. These numbers reflect more than market uptake. They speak to trust in a solution that has been developed carefully, improved iteratively and proven under pressure.One of the most notable applications is the industry's first large-scale methanol retrofit of the 15,000 TEU container ship Maersk Halifax. The project involved integrating a methanol-ready FSS alongside existing fuel infrastructure, and marks a significant step forward for the industry as a whole: demonstrating the viability of large-scale conversions for low-emission operations.The contract was signed with ambitious targets, including customization, engineering and space constraints that necessitated careful execution. Despite the challenge of long lead times for key components – driven by strict class requirements for alternative fuels – we successfully met the tight delivery schedule.

The collaboration between Maersk, the shipyard, engine manufacturer Everllence (formerly MAN Energy Solutions) and Alfa Laval presented unique learning opportunities - encompassing not only the replacement of critical engine components but also the installation of new fuel tanks, a fuel preparation room and an advanced fuel supply system.More than just a technical achievement, the project serves as a blueprint for the future. As shipping accelerates its decarbonization journey, converting existing tonnage to handle cleaner fuels offers a faster, more scalable path to emissions reduction. The lessons learned - ranging from design adaptation and system integration to supply chain coordination and class compliance - will prove invaluable for future projects.

Methanol demands more than just a pump

One of the most common misconceptions we often hear is that switching to methanol is simply a matter of changing the fuel. In reality, it’s a complex process that demands upfront investment, detailed feasibility studies and careful design adaptation. Methanol has a significantly lower flashpoint than diesel, which means it requires dedicated materials, clearly defined interfaces and new safety procedures. It also introduces operational requirements that conventional fuels do not – such as purging lines before inspection and conducting regular leak tests.That’s why our FCM Methanol system goes far beyond simply moving fuel. It incorporates integrated safety features and automated routines to support these additional processes, reducing risk and helping crews manage operations with confidence and precision.In addition, methanol requires careful thermal management due to its corrosive nature and behaviour under heat and pressure. Our heat exchangers - ranging from semi-welded plate models with RefTight™ sealing to compact, stainless-steel AlfaNovaM units - are built to meet these specific demands, engineered not just for performance but for reliability and peace of mind even when your vessels is thousands of miles from shore.

Boilers and heat exchangers also in the frame

Methanol isn’t just for propulsion. To fully leverage it, we need to look at the broader onboard energy system – including boilers.Alfa Laval is proud to have pioneered the world’s first methanol-ready boiler system. Our Aalborg boilers are equipped with the innovative MultiFlame burner concept, which are specially engineered to accommodate methanol’s unique combustion characteristics while also offering seamless compatibility with a variety of other fuel options. This innovation led to the first-ever Approval in Principle (AiP) from a class society (ABS) for methanol operation, following months of rigorous testing at our ultra-modern Alfa Laval Test & Training Centre in Aalborg, Denmark.Couple that with the Aalborg Micro Economizer, and you get more than just compliance; you get a smarter, more efficient energy system that cuts fuel costs and emissions.This capability was demonstrated with the successful commissioning of the world’s first methanol-fired marine boiler system, installed on a 16,000 TEU container vessel operated by a leading Chinese owner. Delivered under a demanding schedule, the project involved new design integration challenges and compliance with emerging class requirements. Alfa Laval's role extended beyond equipment supply, encompassing project planning, engineering, training and on-site commissioning support. The installation benefitted from close collaboration between the yard and Alfa Laval’s R&D, software and commissioning teams, enabling rapid resolution of integration issues and a smooth start-up process. The boiler system, developed and tested at our dedicated Alfa Laval Test & Training Centre, marks a key advancement in bringing methanol into auxiliary energy systems - and further underscores our technical leadership in enabling the use of low-flashpoint alternative fuels.

Capturing every last watt

Let’s not pretend otherwise, methanol is more expensive than conventional fuels. So it's essential to squeeze out every drop of efficiency.Enter the Alfa Laval E-PowerPack. Built on ORC (Organic Rankine Cycle) technology, this smart unit captures waste heat - even from low-temperature sources like engine jacket water - and converts it into electrical power.In simple terms, this makes your methanol-powered vessel more economical to operate, while also improving your CII and EEDI scores.And it does so in a way that’s seamless to integrate, scalable to your needs and maintainable over time. We’ve invested in making the E-PowerPack more than an energy solution – it’s a strategic asset for operators seeking to optimize their vessels for the future.

Innovation and partnerships

Alfa Laval isn’t new to this. We’ve been solving marine challenges for over 100 years and we’ve never stood still. Our Alfa Laval Test & Training Centre continues to push boundaries with cutting-edge research on methanol combustion, system integration and safety protocols.You can’t decarbonise alone; we know that shaping the fuel future isn’t just about technology, it’s about people, policy and partnership. Through joint R&D and shared expertise, we’re accelerating methanol engine readiness for both newbuilds and retrofits, working closely with industry-leading propulsion OEMs like Everllence and WinGD.We're also knitted into broader ecosystems including industry working groups and regulatory initiatives. Meanwhile, our digital solutions - such as StormGeo’s emission monitoring tools - support compliance by providing robust, user-friendly dashboards for managing onboard data and streamlining reporting processes.Just as important is having the right support when and where it matters. Our global service network ensures that whether your vessel is in Shanghai, Rotterdam or Santos, expert assistance is never far away - minimizing downtime and helping you get the most from your methanol systems.In conclusion, every vessel operates under its own constraints. That's why we tailor our solutions to meet your specific needs, whether you're designing a newbuild or retrofitting an existing ship. Our aim is to work alongside you as a trusted partner, ensuring your transition is smooth, efficient and aligned with your long-term fuel strategy.