Marine Series

HydroSave: Advanced Fuel Efficiency Increase System for Marine Engines & Cutting-Edge Fuel Reduction and Emissions Reduction Technology

GSF Technologies specializes in optimizing vessel operational costs through innovative technologies and advanced hydrogen generation solutions. Our mission is clear; significantly reduce fuel usage, lower engine oil consumption, and minimize exhaust emissions.

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  • How HydroSave Marine Works

How it Works

Improving fuel efficiency requires a sophisticated approach and numerous options are available ranging from fuel additives and catalyst injections to oil additives and hull coatings. But with escalating fuel prices and mounting environmental concerns, the most cost effective solution is now clear: enhancing combustion with hydrogen.

Fuel Efficiency Improvement

Improving fuel efficiency requires a complex approach; there are many options—fuel additives, catalyst injection, oil additives, etc. With rising fuel prices and environmental demands, the most cost-effective solution is to enrich the air/fuel mixture with hydrogen.
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Economical, Clean & Green Operation

GSF HydroSave Marine Series uses advanced and efficient electrolysis cells to break water molecules into hydrogen and oxygen, feeding produced hydrogen directly into the engine's air intake. This supplemental hydrogen dramatically improves combustion efficiency, enabling the marine engines to operate cleaner, greener, and more economically than ever before.
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  • HYDROSAVE MARINE SERIES

Information

Why Choose HydroSave Marine Series?

Implementing GSF Technologies’ HydroSave systems positions your business as an environmental leader, providing tangible evidence of your commitment to sustainability. This is not just about reducing operational costs. It’s “marketing gold,” distinguishing your fleet as environmentally responsible, future-ready, and competitive.

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  • HYDROSAVE MARINE SERIES

Why HydroSave

REDUCE OPERATING COSTS AND INCREASE EFFICIENCY WITH A SIMPLE ADDITION

HydroSave Marine Series by GSF Technologies offers shipowners/operators a simple, safe, and quick payback solution to reduce fuel consumption and emissions on existing marine engines. The system is particularly effective on older vessels, where combustion efficiency has typically deteriorated.

How It Works

HydroSave uses onboard electrolysis hydrogen generators to generate pure hydrogen, which is then fed into the engine’s air intake. This improves combustion efficiency, resulting in almost complete fuel burn, cleaner emissions, and direct-immediate operating cost savings.

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Effect of hydrogen enrichment

Effect of hydrogen enrichment (12 L/min per MW) on emissions of a 30 MW marine engine. The values ​​below show typical changes in key pollutants/gases upon addition of ~360 L/min H₂.

Gas / Pollutant
Baseline (without H₂)
With 180 L/min H₂
Change
Reason
CO2 (Carbon Dioxide)
~6,5% vol
~5,9–6,3% vol
Moderate Decrease
Hydrogen combusts almost fully the fuel, reducing CO2 for same shaft power.
CO (Carbon Monoxide)
CO (Carbon Monoxide)
0,4–0,8 g/kWh
Strong Decrease
Hydrogen enables near- complete combustion CO to CO2.
NOx (Nitrogen Oxides)
7–12 g/kWh
9–12 g/kWh
Noticeable Increase
Higher peak temperatures from hydrogen combustion.
HC (Unburned Hydrocarbons)
0,2–0,8 g/kWh
0,05–0,3 g/kWh
Strong Decrease
Efficient oxidation reduces unburned fuel.
O₂ (Oxygen)
10–13,5% vol
8–11% vol
Slight Decrease
More oxygen consumed in hydrogen-enhanced combustion.
PM (Particulate Matter)
0,35 g/kWh
0,1–0,25 g/kWh
Strong Decrease
Hydrogen combustion sharply reduces soot.

Note: Values ​​are indicative and depend on engine setup, loads, fuel and NOx control strategies.

  • HYDROSAVE MARINE SERIES

Case Study – Summary

This case study presents a simulation of hydrogen-enhanced fuel combustion on a large ocean-going vessel equipped with a MAN 6S80MC-C7 main engine and auxiliary generators. Using real operational data and conservative assumptions, the analysis demonstrates that a HydroSave retrofit can deliver validated fuel and emissions savings with very low CAPEX and extremely short payback.

Key outcomes:

  • Fuel savings: ~3.7% annually, equivalent to USD 291,000 per year (based on median fuel prices over the past 24 months).
  • Emissions reduction: ~1,700 mt CO₂ per year, supporting compliance with IMO NZF frameworks.
  • Operational scope: ~14,800 mt annual fuel consumption across main and auxiliary engines.
  • Payback: Achievable within < less than one year at current fuel prices.
  • System design: Modular, compact, no hydrogen storage, no integration into existing engine software or fuel lines.

This assessment positions the technology as a practical first step toward efficiency and decarbonisation, delivering immediate OPEX savings alongside environmental benefits that will gain increasing value as regulatory implementation intensifies.

Vessel Operational Profile

Item
Details
Main engine
MAN 6S80MC‑C7
Original MCR
22,700 kW → derated to 17,769 kW (78.3%)
Typical operational power
~9 MW continuous
Operation at sea
~85% of the year
Year Built
2010
Total operating hours
~96.821
Auxiliary engines
3 × 5DK-20, 745 kW each
AE utilisation
2 online, ~65% uptime, ~315 kW avg. load
Category
Value / Cost
Average 2024 fuel prices
HFO: USD 515/mt · VLSFO: USD 626/mt
Main engine fuel cost
USD 7.04 million
Auxiliary engines fuel cost
USD 0.83 million
Total fuel cost
USD 7.87 million (excluding boiler fuel)
ITEM
COST
Hydrogen Generators
TBD
Cabling / Electrical Board
TBD
TracPipe Piping & Manifolds
TBD
Detector / Automatic Cut-off Switch
TBD
Total Equipment Cost
TBD
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  • HYDROSAVE MARINE SERIES​

System Operation & Safety Overview

The GSF Technologies HydroSave Marine Series is a modular water electrolysis system that produces pure hydrogen on demand. The hydrogen is supplied directly to the engine air intake.
HydroSave is designed to improve combustion efficiency and reduce fuel consumption in marine engines, with absolute priority on safety, simplicity of design, and minimal interference with onboard systems.

System Overview

  • Electrolysis System: Pure hydrogen is produced from distilled water using KOH as electrolyte. There is no onboard hydrogen storage, eliminating risks associated with storage and high pressure.
  • Direct Utilization: Hydrogen is injected directly into the engine’s turbo / air intake through a dedicated gas line, improving combustion quality and increasing thermal efficiency.
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  • HYDROSAVE - MARINE SERIES

Multimedia / Case Studies

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Contact

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