Shipbuilding Industrial Cluster of Japan
Shipbuilding Industrial Cluster of Japan How Japan strengthens innovation and collaboration between education, research and industry within the marine industry 16th of May 1
Natori City, Miyagi Prefecture
2
Influences of Earthquake and subsequent Tsunami
Sapporo Sendai A
1. Aftercare of the people who lost their family, home, and job 2. Radioactive matters from troubled Nuclear Station 3. Shortage of electricity in 50Hz area
Most Tsunami Effected Coast
B C
D
60Hz
50Hz
Mitsui Tamano Hiroshima
E
Nuclear Station in trouble
Tokyo
Nagoya Kyoto F Kobe Osaka
Fukuoka
Major Shipyards Major Cities Monitor Places 3
20 11 /3 /1 20 3 11 /3 /1 20 5 11 /3 /1 20 7 11 /3 /1 20 9 11 /3 /2 20 1 11 /3 /2 20 3 11 /3 /2 20 5 11 /3 /2 20 7 11 /3 /2 20 9 11 /3 /3 1 20 11 /4 /2 20 11 /4 /4 20 11 /4 /6 20 11 / 20 4/ 8 11 /4 /1 20 0 11 /4 /1 20 2 11 /4 /1 20 4 11 /4 /1 20 6 11 /4 /1 8
Mic ro Sv/ hour
Radioactive level : highest on the 15th of March, keeps going down Measured Radioac t ive Level
30
25
20
15
A C B D E
10
5
0
Norway 1.2
Dat e
4
20 11 /3 /1 20 3 11 /3 /1 20 5 11 /3 /1 20 7 11 /3 /1 20 9 11 /3 /2 20 1 11 /3 /2 20 3 11 /3 /2 20 5 11 /3 /2 20 7 11 /3 /2 20 9 11 /3 /3 1 20 11 /4 /2 20 11 /4 /4 20 11 /4 /6 20 11 / 20 4/ 8 11 /4 /1 20 0 11 /4 /1 20 2 11 /4 /1 20 4 11 /4 /1 20 6 11 /4 /1 8
Mic ro Sv/ hour
Radioactive level : Tokyo is already at normal condition Measured Radioac t ive Level
0.9
0.8
0.7
0.6
0.5
Italy 0.5 Germany 0.43
0.4
0.3
0.1
0.0
Date
Sendai Tokyo Sapporo F
France 0.25
0.2
Denmark 0.051
5
Production Results of MITSUI-MAN B&W Diesel Engine
70 mil ps
50 mil ps
40 mil ps
（Line Cart)
（Bar Cart)
60 mil ps
30 mil ps
License Contract since 1926
20 mil ps
“A” shop completed
Constant Pressure System 10 mil ps NO.1 Engine
(based on Engine test run start)
Turbocharger introduced
6
Low-Speed Engine Production Record in Japan Expansion of Production Capacity to 6 mill. BHP
Annual Production ×10
４
BHP
Expansion of Production Capacity to 5 mill. BHP
The second Depression of shipbuilding Construction amount: 4.5 mill. GT
Expansion of Production Capacity to 4 mill. BHP
Started operating a New Shop
Investment to Chinese DE maker
（Note：Large low speed 2 cycle engine。Except land use. 7 Except medium speed engine）
New Building Ship Price (US$) Bulk Carrier Ship Types 船価_バルクキャリ アー_USD Million USD
Capesize BC (above 155k dwt )
Panamax BC (above 70k dwt)
100.0
Handymax BC (above 40k dwt) 94.5
90.0 80.0 70.0 60.0
53.1
55.5
50.0 40.0
46.9 35.0
30.0 21.1
34.5 31.0
20.0 18.8 10.0 0.0
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
8
New Building Ship Price (Japanese \) 船価_バルクキャリ Bulk Carrier Shipアー_日本円 Types Capesize BC (above 155k dwt)
Panamax BC (above 70k dwt)
Handymax BC (above 40k dwt )
120.0
97.4
100 億円million \
100.0
80.0
60.0
54.7 43.9
40.0
45.6 48.4
26.4 20.0
0.0
23.6
1992
1993
1994 1995 1996 1997 1998 1999 2000
2001 2002 2003 2004 2005 2006 2007 2008
28.3 25.5
2009 2010 2011
9
M ar-11
Jan-11
Nov-10
Sep-10
Jul-10
M ay-10
M ar-10
Jan-10
Nov-09
Sep-09
Jul-09
M ay-09
M ar-09
Jan-09
20
Nov-08
Sep-08
Jul-08
M ay-08
M ar-08
Jan-08
Nov-07
Sep-07
Jul-07
M ay-07
M ar-07
Jan-07
Exchange rate makes it difficult to get new order of ship
Trend of Currency Values against US$
160
140
120
～60%
100
J.YEN K.WON C.YUAN
80
60
40
Lehman Shock
0
10
Japanese Shipbuilding Industry Cluster Government
Development Support
Ship Operators (3 giants + )
Trading Co.
Banks Ship Owners 90% of Ships ordered to Japanese yards so far
75% of Ships are for Japanese owners Ship Yards About 130,000 people involved
95% domestic production
Ship Equipment Industry 11
Situation of Japanese Shipbuilding Industry
-Too much orderbook volume for Bulk Carriers Big over capacity of fleet is seen Japanese shipyards prefer Bulk Carriers
- High Japanese Yen Difficult for Japanese shipyards to get orders now Technical Innovation is needed Focus is on CO2 reduction
12
Proposed New Ships by Japanese Shipbuilding Industry CO2 reduction effort both on Hull and Engine required
30% CO2 reduction 66BC by Mitsui
35% CO2 reduction container by Mitsubishi 13
Proposed New Ships by Japanese Shipbuilding Industry Development by Mitsubishi 12% CO2 reduction claimed
Air Lubrication System to reduce traction
Two ships already in service
14
Development by Mitsui Engine Business Unit Partial Financial Support from Government and NK
NOx reduction
CO2 reduction
EGR (MDT) SCR
VTA (MDT) EGS
ME-GI (MDT *) THS
SOx reduction
WHR
*Gas Injection Engine
ORC
was first built by Mitsui in 1994
Scrubber
Obtaining suggestions from University 15 20,000 hrs of operation
Mitsui Test Engine Notation 4S50ME-T Bore/Stroke 500/2,214 mm Number of Cylinders 4 Output 7,460 kW Engine Speed 117rpm Turbocharger TCA55 with VTA Based on S50ME-B9 Completed at the end of 2010 Tests in cooperation with MDT will be scheduled.
16
Test Engine Arrangement
VTA EGR
THS
SCR
Turbo Charger
17 17
THS Development Turbo Hydraulic System (THS) Excess Efficiency of T/C is used
High Speed Hydraulic Pump Power Control Hydraulic Pump
Hydraulic Power Unit Low Speed Hydraulic Motor
18
EGS (Exhaust Gas Separation) Hot gas comes out first, and cool gas next.
Combusted gas
Scavenging air
High Temp Low Temp
Development of special valve having a sub valve
Sub Valve Main Valve
High Temperature gas has higher potential energy to be used 19
EGS Test (1 cylinder Test Engine) 80 degrees C increase of exhaust gas temperature has been obtained !! Separation valve
More excess energy taken from T/C
T/C
Low temp. receiver
And Exhaust gas can be NOx treated by SCR placed after T/C
Exhaust gas temperature ( deg-C )
High temp. receiver Low temp. receive High temp. receiver Conventional
600 500 400
EGS cooler EGS blower
300
Air cooler
200 100 0 25
50
75
Engine load ( % )
90
20
CIMAC Bergen 2010 Best Paper Award To be tested on 4 cylinder Test Engine Separation Valve
Low Temperature Receiver
Sub Valve
High Temperature Receiver High Temperature
Low Temperature
Main Valve
Separation Valve Mechanism 21
Natori City, Miyagi Prefecture
2
Influences of Earthquake and subsequent Tsunami
Sapporo Sendai A
1. Aftercare of the people who lost their family, home, and job 2. Radioactive matters from troubled Nuclear Station 3. Shortage of electricity in 50Hz area
Most Tsunami Effected Coast
B C
D
60Hz
50Hz
Mitsui Tamano Hiroshima
E
Nuclear Station in trouble
Tokyo
Nagoya Kyoto F Kobe Osaka
Fukuoka
Major Shipyards Major Cities Monitor Places 3
20 11 /3 /1 20 3 11 /3 /1 20 5 11 /3 /1 20 7 11 /3 /1 20 9 11 /3 /2 20 1 11 /3 /2 20 3 11 /3 /2 20 5 11 /3 /2 20 7 11 /3 /2 20 9 11 /3 /3 1 20 11 /4 /2 20 11 /4 /4 20 11 /4 /6 20 11 / 20 4/ 8 11 /4 /1 20 0 11 /4 /1 20 2 11 /4 /1 20 4 11 /4 /1 20 6 11 /4 /1 8
Mic ro Sv/ hour
Radioactive level : highest on the 15th of March, keeps going down Measured Radioac t ive Level
30
25
20
15
A C B D E
10
5
0
Norway 1.2
Dat e
4
20 11 /3 /1 20 3 11 /3 /1 20 5 11 /3 /1 20 7 11 /3 /1 20 9 11 /3 /2 20 1 11 /3 /2 20 3 11 /3 /2 20 5 11 /3 /2 20 7 11 /3 /2 20 9 11 /3 /3 1 20 11 /4 /2 20 11 /4 /4 20 11 /4 /6 20 11 / 20 4/ 8 11 /4 /1 20 0 11 /4 /1 20 2 11 /4 /1 20 4 11 /4 /1 20 6 11 /4 /1 8
Mic ro Sv/ hour
Radioactive level : Tokyo is already at normal condition Measured Radioac t ive Level
0.9
0.8
0.7
0.6
0.5
Italy 0.5 Germany 0.43
0.4
0.3
0.1
0.0
Date
Sendai Tokyo Sapporo F
France 0.25
0.2
Denmark 0.051
5
Production Results of MITSUI-MAN B&W Diesel Engine
70 mil ps
50 mil ps
40 mil ps
（Line Cart)
（Bar Cart)
60 mil ps
30 mil ps
License Contract since 1926
20 mil ps
“A” shop completed
Constant Pressure System 10 mil ps NO.1 Engine
(based on Engine test run start)
Turbocharger introduced
6
Low-Speed Engine Production Record in Japan Expansion of Production Capacity to 6 mill. BHP
Annual Production ×10
４
BHP
Expansion of Production Capacity to 5 mill. BHP
The second Depression of shipbuilding Construction amount: 4.5 mill. GT
Expansion of Production Capacity to 4 mill. BHP
Started operating a New Shop
Investment to Chinese DE maker
（Note：Large low speed 2 cycle engine。Except land use. 7 Except medium speed engine）
New Building Ship Price (US$) Bulk Carrier Ship Types 船価_バルクキャリ アー_USD Million USD
Capesize BC (above 155k dwt )
Panamax BC (above 70k dwt)
100.0
Handymax BC (above 40k dwt) 94.5
90.0 80.0 70.0 60.0
53.1
55.5
50.0 40.0
46.9 35.0
30.0 21.1
34.5 31.0
20.0 18.8 10.0 0.0
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
8
New Building Ship Price (Japanese \) 船価_バルクキャリ Bulk Carrier Shipアー_日本円 Types Capesize BC (above 155k dwt)
Panamax BC (above 70k dwt)
Handymax BC (above 40k dwt )
120.0
97.4
100 億円million \
100.0
80.0
60.0
54.7 43.9
40.0
45.6 48.4
26.4 20.0
0.0
23.6
1992
1993
1994 1995 1996 1997 1998 1999 2000
2001 2002 2003 2004 2005 2006 2007 2008
28.3 25.5
2009 2010 2011
9
M ar-11
Jan-11
Nov-10
Sep-10
Jul-10
M ay-10
M ar-10
Jan-10
Nov-09
Sep-09
Jul-09
M ay-09
M ar-09
Jan-09
20
Nov-08
Sep-08
Jul-08
M ay-08
M ar-08
Jan-08
Nov-07
Sep-07
Jul-07
M ay-07
M ar-07
Jan-07
Exchange rate makes it difficult to get new order of ship
Trend of Currency Values against US$
160
140
120
～60%
100
J.YEN K.WON C.YUAN
80
60
40
Lehman Shock
0
10
Japanese Shipbuilding Industry Cluster Government
Development Support
Ship Operators (3 giants + )
Trading Co.
Banks Ship Owners 90% of Ships ordered to Japanese yards so far
75% of Ships are for Japanese owners Ship Yards About 130,000 people involved
95% domestic production
Ship Equipment Industry 11
Situation of Japanese Shipbuilding Industry
-Too much orderbook volume for Bulk Carriers Big over capacity of fleet is seen Japanese shipyards prefer Bulk Carriers
- High Japanese Yen Difficult for Japanese shipyards to get orders now Technical Innovation is needed Focus is on CO2 reduction
12
Proposed New Ships by Japanese Shipbuilding Industry CO2 reduction effort both on Hull and Engine required
30% CO2 reduction 66BC by Mitsui
35% CO2 reduction container by Mitsubishi 13
Proposed New Ships by Japanese Shipbuilding Industry Development by Mitsubishi 12% CO2 reduction claimed
Air Lubrication System to reduce traction
Two ships already in service
14
Development by Mitsui Engine Business Unit Partial Financial Support from Government and NK
NOx reduction
CO2 reduction
EGR (MDT) SCR
VTA (MDT) EGS
ME-GI (MDT *) THS
SOx reduction
WHR
*Gas Injection Engine
ORC
was first built by Mitsui in 1994
Scrubber
Obtaining suggestions from University 15 20,000 hrs of operation
Mitsui Test Engine Notation 4S50ME-T Bore/Stroke 500/2,214 mm Number of Cylinders 4 Output 7,460 kW Engine Speed 117rpm Turbocharger TCA55 with VTA Based on S50ME-B9 Completed at the end of 2010 Tests in cooperation with MDT will be scheduled.
16
Test Engine Arrangement
VTA EGR
THS
SCR
Turbo Charger
17 17
THS Development Turbo Hydraulic System (THS) Excess Efficiency of T/C is used
High Speed Hydraulic Pump Power Control Hydraulic Pump
Hydraulic Power Unit Low Speed Hydraulic Motor
18
EGS (Exhaust Gas Separation) Hot gas comes out first, and cool gas next.
Combusted gas
Scavenging air
High Temp Low Temp
Development of special valve having a sub valve
Sub Valve Main Valve
High Temperature gas has higher potential energy to be used 19
EGS Test (1 cylinder Test Engine) 80 degrees C increase of exhaust gas temperature has been obtained !! Separation valve
More excess energy taken from T/C
T/C
Low temp. receiver
And Exhaust gas can be NOx treated by SCR placed after T/C
Exhaust gas temperature ( deg-C )
High temp. receiver Low temp. receive High temp. receiver Conventional
600 500 400
EGS cooler EGS blower
300
Air cooler
200 100 0 25
50
75
Engine load ( % )
90
20
CIMAC Bergen 2010 Best Paper Award To be tested on 4 cylinder Test Engine Separation Valve
Low Temperature Receiver
Sub Valve
High Temperature Receiver High Temperature
Low Temperature
Main Valve
Separation Valve Mechanism 21
