EcoNavis receives U.S. Federal Grant by NFWF to study on integrated propulsion optimisation
Eco Boss Cap technology and cavitation comparison
EcoNavis Solutions has been selected by a U.S. Federal Government agency to lead a federally backed project aimed at demonstrating how integrated hydrodynamic optimisation can reduce fuel consumption and underwater radiated noise in offshore vessels and workboats operating in the Gulf of Mexico.
The award, valued at US$500,000, will support a full-scale retrofit and validation programme on a designated workboat, with the objective of establishing a repeatable framework for improving propulsion efficiency while addressing increasing scrutiny around underwater radiated noise.
Integrated approach to vessel performance
Rather than assessing individual technologies in isolation, the project will evaluate the combined impact of multiple energy-saving devices applied as an integrated system. The approach reflects a broader shift within the industry towards whole-vessel performance, particularly as operators face more stringent emissions and environmental rules along with rising fuel costs.
Dr Batuhan Aktas, Founder and CEO of EcoNavis Solutions, said the programme is designed to move beyond theoretical gains and deliver measurable operational results.
“This project allows us to validate, at full scale, how an integrated set of hydrodynamic technologies can improve propulsion efficiency and reduce underwater noise in real operating conditions,” he said. “The focus is not on a single device, but on how the entire propulsion train can be optimised and verified through data.”
Technical scope
The technical scope centres on the integration of a new flow-aligned twisted rudder, dubbed EcoVane; EcoNavis’ proprietary propeller hub Eco Boss Cap; and pressure-relieving modifications to the propeller blades. Each element targets a different source of hydrodynamic loss, from wake misalignment and drag at the rudder to vortex formation and cavitation at the propeller hub and blades.
“By addressing these effects collectively, the project is expected to deliver efficiency improvements of around five per cent, alongside a reduction in underwater radiated noise of more than three decibels,” said Dr Aktas.
The figures will be validated through controlled before-and-after sea trials, including direct measurement of shaft power and acoustic output.
Methodology and standards
The work will begin with computational modelling to establish a performance baseline for the selected vessel, followed by iterative design optimisation using vessel-specific flow analysis. Manufacturing, installation and full-scale trials will then be carried out, with all performance data collected and verified using recognised international standards, including ISO 15016 for fuel efficiency and ISO 17208-1 for underwater noise measurement.
EcoNavis will lead the hydrodynamic design and simulation work, supported by a consortium of propulsion specialists that include King Propulsion, CJR Propulsion and Oscar Propulsion.
Duncan Troy, the CEO of project partner Oscar Propulsion, the company behind the novel PressurePores technology where holes on the propeller blades mitigate cavitation noise, said: “The Gulf of Mexico has been identified as a key operating environment for the programme, given the high concentration of offshore support, harbour and crew transfer vessels, as well as increasing regulatory focus on both emissions and acoustic impact on marine ecosystems.
“The industry is under pressure from both fuel costs and regulation. What owners need are solutions that are not only technically effective, but commercially realistic. This project is about proving both.”
The project will also draw on established class approval and manufacturing processes to ensure that the solutions are scalable and suitable for wider fleet adoption. Beyond the demonstration vessel, the programme aims to generate a validated dataset that can support wider deployment across similar vessel classes.
EcoNavis said further updates, including details of the selected vessel and trial results, will be released as the project progresses.
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New tests confirm Eco Boss Cap efficiency as pilot installation planned
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A second series of cavitation tests has confirmed that the Eco Boss Cap propeller hub improves fuel efficiency by up to 5% at full scale, as shipowners and propeller manufacturers express interest in the technology.
Full-scale CFD simulation of a ship operating at a design speed of 16.46 knots and turning a controllable pitch propeller with four different boss cap models found the Eco Boss Cap to be the more efficient solution, outperforming existing hubs by a factor of 2.5 or more.
According to the trials report, researchers concluded that propeller hub vortex cavitation was significantly eliminated by the holes in the Eco Boss Cap models, with vortex cavitation disappearing after interaction with the holes.
The test results mean that the simple-to-manufacture and install propeller hub can be retrofitted to large ocean-going ships as a way of contributing to shipowner ESG goals to reduce carbon emissions.
Eco Boss Cap inventor Dr Batuhan Aktas, a Chancellor’s Fellow in the Naval Architecture, Ocean and Marine Engineering Department at the University of Strathclyde, said: “Our approach to improving propeller efficiency is unique in both design and application. It diverges from traditional methods that typically use propeller hub fins to achieve similar outcomes. We are receiving a tremendous amount of industry interest.”
A key differentiating aspect of the Eco Boss Cap is the emphasis on cost-effectiveness and ease of manufacturing. Unlike conventional propeller boss cap fins (PBCF) which are complex and expensive to produce, the Eco Boss Cap offers a simpler and more economical solution without compromising on efficiency or performance.
Ship maintenance costs can also be reduced as propeller hub vortex cavitation is the primary source of rudder cavitation and damage. In addition, the Eco Boss Cap reduces underwater radiated noise and vibration levels, which impacts the migratory, mating and feeding habits of marine mammals.
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EcoNavis develops hydrodynamic energy-saving devices tailored to each vessel’s hull, propeller and rudder interaction. To assess whether Eco Boss Cap or an integrated optimisation package may be suitable for your fleet, contact the EcoNavis team.
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Eco Boss Cap validated as more efficient than existing propeller hub caps
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A revolutionary propeller hub vortex cavitation-eliminating boss cap has successfully completed validation tests at a hydrodynamic research centre in Sweden and will now undergo ship model basin trials to verify the efficiency gains on larger commercial and naval vessels.
Initial computational fluid dynamics (CFD) tests based on a typical twin-screw vessel with V-brackets and a 90 m coastal general cargo ship showed that the Eco Boss Cap increases propulsion efficiency by up to 5%, compared to conventional propeller boss caps. Tests also assessed the device against more advanced energy-efficient boss caps currently in operation, and found it to be at least 3% more efficient.
“Overall, compared to the propeller boss caps currently available, the Eco Boss Cap improved propeller efficiency by 3.1% and thrust by 1.1%, while reducing torque by 2%, rudder cavitation by 10%, and propeller-induced noise by 1–3 dB,” explained Dr Batuhan Aktas.
“The Eco Boss Cap eliminates completely propeller hub vortex cavitation, the main source of rudder erosion, and reduces associated propeller efficiency losses, which can be as much as 8%.
“Considering the investment levels required for other energy-saving devices currently in the market and the potential fuel savings, the Eco Boss Cap represents a significant advantage with a return on investment of less than six months,” he said.
How it works
The holes channelled into the Eco Boss Cap affect the high pressure in the hub vortex by redirecting the flow downstream. The resulting low-pressure swirl flows in the opposite direction to conventional hubs, behind the propeller blades, reducing propulsive drag, fuel consumption and maintenance costs.
“With shipowners grappling with new environmental legislation and emissions reporting rules, zero propeller hub vortex cavitation can help towards ESG, EEXI and CII goals, improve efficiency and reduce the costs associated with cavitation-induced rudder erosion.”
The Eco Boss Cap is reportedly less expensive than conventional propeller hub cap fins that incorporate small blades or fins to hydrodynamically deflect the water flow, as it is easier to cast and requires less material.
“What we have designed is a propeller boss cap that is 5% more efficient and costs 50% less to manufacture than current conventional propeller hubs. Considering the minimal investment required, this is a significant level of saving.”
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