Optimizing Hybrid Cruise Vessels Performance With Industry 5.0 Driven Digital Twins: Efficiency Improvement and Emissions Reduction

ABSTRACT Despite the advances in Industry 5.0 potential through digital twins, limited research has examined how human‐centered digital twins can support the evaluation of battery‐supported hybrid cruise vessels to improve operational and environmental performance. This research examines the operational savings and emissions reduction (reducing emissions of Carbon Dioxide [CO 2 ], Sulfur Oxide [SOx], Nitrogen Oxide [NOx], and Particulate Matter [PM]) that can be realized across different types of cruise vessels through the integration of data‐driven batteries with Industry 5.0 digital twin. Data were collected from a case study of Wärtsilä, a leading Finnish maritime firm, and operationalized using human centered digital twins of two hybrid cruise vessels to assess the impact on operations, environmental performance, and carbon intensity. Findings show that battery‐supported hybrid systems can reduce annual operating costs by €100,000–€600,000 and lower annual carbon emissions by up to 3000 tons. Integrating shore power further improves performance by generating additional annual savings of approximately €40,000 while substantially reducing port‐side emissions. The results also show that battery performance depends on battery size, C‐rate, and vessel operating profile. Larger batteries generally improve fuel efficiency and reduce engine running hours, although the economic benefits diminish beyond the optimal battery size. Smaller batteries experience faster degradation and provide lower operational benefits. This study extends the maritime sustainability literature by demonstrating how human‐centered Industry 5.0 digital twins can support battery integration decisions in hybrid cruise vessels. Proposed framework provides a practical decision‐support approach for improving operational efficiency while accelerating the decarbonization of the cruise industry.