Research on Capacity Parameter Matching and Robust Design of a Methanol Range-Extended Series Hybrid Powertrain System for Harbor Tugs

To address the stringent emission regulations of the International Maritime Organization (IMO) and the growing demand for green port operations, this study proposes an innovative range-extended series hybrid powertrain system featuring a dedicated methanol engine as an Auxiliary Power Unit (APU) for harbor tugs. Based on an analysis of actual ship operational data, a core design paradigm of “battery-dominant, engine-as-range-extender” is established. A robust capacity parameter matching method is proposed, yielding a configuration comprising a 200 kW∙h/600 kW Lithium Iron Phosphate Battery Pack (LFPBP), a 250 kW methanol APU, and a 400/600 kW Permanent Magnet Synchronous Propulsion Motor (PMSM). A hierarchical intelligent energy management strategy (EMS), integrating state-machine coordination and real-time power allocation, is designed. High-fidelity simulations under a typical duty cycle demonstrate that the proposed system achieves an equivalent fuel-saving rate of 50.8% compared with a conventional diesel system, with the engine operating exclusively in its high-efficiency zone (>42% efficiency) for only 35% of the operational time. A full life-cycle techno-economic analysis reveals an incremental investment payback period (PBP) of approximately 3 months and a net present value (NPV) exceeding USD 9.69 million over a 10-year period. Quantitative environmental analysis shows an annual reduction of approximately 94.8% in CO2 emissions (assuming the use of green methanol produced from renewable sources and captured CO2), 95% in NOx emissions, and the near-elimination of SOx and particulate matter (PM). This study provides a systematic and economically attractive solution with promising engineering feasibility verified by simulation, which paves the way for further experimental validation and practical engineering implementation.