3.3.2 Basic Concept of Ship Breaking Project
1) Main facilities
The ship breaking project is composed of the ship breaking dock and the re-rolling mill. The ship breaking yard is planned to carry out scrapping works systemically not only for VLCCS but also for large bulk carriers, liquefied gas carriers, container ships, etc., considering supply fluctuation of ships after the forecasted peak time of a lot of large tankers to be scrapped. The re-rolling mill is to recycle the scrapped steel to a round re-bar for the construction use.
Estimated annual breaking capacity in the yard is eight (8) VLCCs, that is, total annual breaking LDT is around 250,000 LDT. The max capacity of one re-rolling mill is estimated to be 5,000 ton/month and then two (2) mills are to be constructed.
2) Dimension of the Project
The dock's dimensions, yard area, equipments and facilities are designed through taking the effircient scrapping works and a management of safe and efficient operation into consideration. The required conditions for those purposes are as follows:
a) Stable operation of the yard facilities
In order to keep the yard operation as stable as possible through a financial term of a year, warehouse and stock yard with sufficient space shall be prepared.
b) Safety measures for workers
Sufficient measures will be taken to insure the workers from potential casualties such as residual gas explosions, hazardous materials generated, fall out of broken pieces and blocks.
c) Consideration on environmental preservation
Ship-breaking docks without any oil spillage shall be introduced for preserving the coastal sea area. Waste oily water generated from ship-breaking dock must be treated by the oil treatment plant before discharging in to the sea.
d) Product re-cycling as recoveries
Recovered steels are classified by three categories of which re-usable steel, re-rollable steel, and melting steel scrap. To increase an additional value of re-rollable steel, a re-rolling mill is most important facility related to the ship-scrapping project. The workshop and warehouses will have to be closely incorporated for reconditioning recovered machinery, equipment and tools and for storing supply depending on the market.
Systematic procedures for cutting from large blocks and to sorting of such recoveries or to keep some of them stored at the warehouse should be considered. Management technique for the yard operation will have to be introduced from a highly industrially developed country like Japan, in order to secure the high productivity.
f) Minimized Investment
Initial investment will have to be minimized in order to keep the yard and facilities at a reasonable work level.
g) Early completion of the construction
It is essential to construct the yard as short as possible so as to cover the global down of the ship-breaking capacity.
h) Technology transfer
Technology transfer, from such highly industrialized like Japan, is prerequisite particularly in terms of Engineering and Management aspects. In particular, the engineers with a sufficient experience on the ship-breaking and re-rolling of a scrapped steel should be get involved with the technology transfer.