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BULK CARRIER
A bulk carrier, bulk freighter, or bulker is a merchant ship specially designed to transport
unpackaged bulk cargo, such as grains, coal, ore, and cement in its cargo holds.There are
various ways to define the term bulk carrier. As of 1999, the International Convention for the
Safety of Life at Sea defines a bulk carrier as "a ship constructed with a single deck, top side
tanks and hopper side tanks in cargo spaces and intended to primarily carry dry cargo in bulk;
an ore carrier; or a combination carrier." However, most classification societies use a broader
definition where a bulker is any ship that carries dry unpackaged goods.
The first specialized bulk carrier was built in 1852, economic forces have fuelled the
development of these ships, causing them to grow in size and sophistication. Today's bulkers
are specially designed to maximize capacity, safety, efficiency, and to be able to withstand the
rigorous of their work.
Today, bulkers make up 40% of the world's merchant fleets and range in size from singlehold mini-bulkers to mammoth ore ships able to carry 400,000 metric tons of deadweight
(DWT). A number of specialized designs exist: some can unload their own cargo, some
depend on port facilities for unloading, and some even package the cargo as it is loaded. Over
half of all bulkers have Greek, Japanese, or Chinese owners and more than a quarter are
registered in Panama. Korea is the largest single builder of bulkers, and 82% of these ships
were built in Asia.
Literature Review
Bulk Carrier Types
Ore Carriers
Ore carriers are specially designed and may only be employed for a specific trade, eg carriage
of iron ore in bulk from major Australian or Brazilian ports to specific ports in China or
Japan.Ships that are designated as ore carriers have to be strengthened by class standards. In a
seaway these ships tend to be stiffer due to the high density of ore cargoes.
Oil/Bulk/Ore OBO Ships
These ships were designed to alternate between dry bulk and oil cargoes, avoiding a nonearning ballast passage by carrying both cargoes in the same cargo spaces at different times.
They were designed with large hatches to facilitate loading and discharging. However, the
hatch covers were designed to be `oil tight' so the same ship could be loaded with oil cargoes
with strengthened holds for ore cargoes. For this dual purpose operation, OBOs were fitted
with pipelines, pumps and other oil tanker equipment. Major problems on these ships
included gas freeing to load dry cargo after an oil cargo and the high maintenance costs
caused by heavy wear and tear. Owing to the number of losses, notably the Berg Istra (1976),
Berg Vanga (1979) and the Derbyshire (1980), combined with the high maintenance costs,
there has been a reduction in the number of these ships, with few new OBOs built. Most
remaining OBOs are limited to one cargo type.
OBO construction is similar to that of a bulk carrier except that they have larger wing tanks
and their DB tanks are deeper to improve stability when carrying ore cargoes. Many OBOs
have void spaces formed by fitting transverse bulkheads between two cargo holds.
Tank/hold cleaning system similar to the crude oil washing system on oil tankers
ullaging equipment
Pipeline system (ballast, bilge and cargo) fitted through the duct keel
loading/ unloading equipment including cranes, grab buckets and wings with
conveyor belts on deck (to pour the chips into cargo holds).
When discharging, the ship's cranes are used together with a grab bucket system
running at the bottom of the cargo compartments. The cargo is carried to the
forecastle by conveyor, where it is discharged ashore through a single discharging
point. However, many ships use conventional grabs to discharge the cargo.
Timber Carriers
These vessels are used for carrying timber or logs in the holds and on deck. The
machinery space and accommodation are located aft to provide clear deck space for
the cargo. Generally, they are fitted with cranes that can handle logs that weight up to
25 tonnes. This means that the decks, tanktops, hatch covers and other structures are
additionally strengthened to withstand these loads.
These ships usually have fixed or portable uprights to support logs/ timbers lashed on
deck. It must be ensured that there is clear access to the mast houses, sounding pipes,
etc, during loaded voyages.
These vessels carry lashings that include turnbuckles, wire ropes, chain, etc, fitted
with a quick release mechanism such as a senhouse slip to release the deck cargo in
case of emergency. On some ships, air powered `speedlashings' automate the lashing
and tightening procedure.
The ship's lashing plan should be adhered to as prescribed in the approved cargo
loading manual. The Code of Safe Practice for Ships Carrying Timber Deck Cargoes
should be complied with for the carriage of timber on these ships.
A double skin enhances safety, security, dependability, reliability, and reduces the
possibility of damage from accidental flooding. In addition, structures such as frames
and brackets located inside the double skin structure provide a smooth surface for the
cargo, reducing problems with inspection or maintenance. The potential for damage
caused by cargo gear like grabs or bulldozers is reduced, increasing the speed of cargo
discharging in port. The double hull makes inspection much easier through the use of
passageways, ladders and manholes in the double skin. Ballast capacity is also
increased, which is an added advantage in ballast voyages.
Typical Cargo
Minor
bulk,
Handysize
25,000
between
Lakesize
and 40,000
between 20,000 to pass through St. Lawrence
27,000
Steel
products,General Cargo.
Minor bulk, Steel products
Handymax
between
Panamax
and 60,000
Grain, Coal
between
60,000 It usually contains seven Bauxite, Coal,
and 100,000 tonnes
holds.
These
have
to
be
bulk,
max. Phosphate
done,
Minor
Steel
products,
Grain,
Ore,
Post-
between
Panamax
Capesize
Hope.
entirely
on
shore
are
handled
the
discharging.
It usually contain nine holds. Coal, Ore
Large
Carriers)
Bulk
entirely
on
shore
are
handled
the
1. Choosing a Design:
The history of ship design is one of evolution rather than revolution. Designers learn from
past experience and each new ship tends to be a development of a previous successful design.
The characteristics desired by the shipping company can usually be achieved with various
combinations of dimensions. This choice allows an economic optimum to be obtained whilst
meeting company requirements. An iterative procedure is needed when determining the main
dimensions and ratios.
1.1 Single hull vs. Double hull:
A double hull bulk carrier can be defined as a ship designed for the carriage of oil
mainly in bulk where the cargo spaces are protected from the environment by a
double hull consisting of double side and double bottom spaces dedicated to the
carriage of ballast water.
Ability to prevent or reduce oil spills led DB HULL being standardized for other types of
ships including Bulk carriers by the International Convention for the Prevention of Pollution
from Ships or MARPOL Convention.
After the Exxon Valdez oil spill disaster, when that ship grounded on Bligh
Reef outside the port of Valdez in Alaska, the US Government required all
new oil tankers built for use between US ports to be equipped with a full
double hull. However, the damage to the Exxon Valdez penetrated sections
of the hull (the slops oil tanks) which were protected by a partial double
hull. The double hull required by the new regulations would not have
prevented extensive loss of oil from the Exxon Valdez, though it might
have somewhat limited the losses.
Furthermore, a double-hulled Bulk carrier doesn't need longitudinal
bulkheads for longitudinal strength, as the inner hull already provides this.
Eliminating longitudinal bulkheads would result in much wider tanks,
significantly increasing the free surface effect. However, this problem is
easily corrected with the addition of anti-slosh baffles and partial bulkheads
2. Design Criteria:
So to satisfy the owners requirements the dimensions of a ship should be co-ordinate such
that the ship satisfies the design conditions. However, the ship should not be larger than
necessary. The design should offer smarter shipping by reducing fuel costs with an optimized
hull form, and by increasing revenues with greater cargo capacity.
It has been said that the problem for a Naval Architect is to design a ship that will carry
certain deadweight at a reasonable rate of stowage in a seaworthy vessel at a predetermined
speed on a given radius of action as cheaply as possible all in conjunction with a General
Arrangement suited to the ships trade.
The Naval Architect must therefore keep in mind all of the following:
In determining the Main Dimensions for a new ship, guidance can be taken from a similar
ship for which basic details are known. This is known as a basic vessel and must be similar
in type, size, speed and power to the new vessel. It is constantly referred to as the new design
is being developed. When a ship owner makes an initial enquiry, he usually gives the
shipbuilder four items of information:
_ Type of vessel
_ Deadweight of the new ship
_ required service speed
_ Route on which the new vessel will operate
i) Prior to loading bulk cargo, the shipper should declare characteristics & density of the
cargo, stowage factor, angle of repose, amounts and special properties.
ii) Cargo availability and any special requirements for the sequencing of cargo operations.
iii) Characteristics of the loading or unloading equipment including number of loaders and
unloaders to be used, their ranges of movement, and the terminal's nominal and maximum
loading and unloading rates, where applicable.
iv) Minimum depth of water alongside the berth and in the fairway channels.
v) Water density at the berth.
vi) Air draught restrictions at the berth.
vii) Maximum sailing draught and minimum draught for safe manoeuvring permitted by the
port authority.
viii) The amount of cargo remaining on the conveyor belt which will be loaded onboard the
ship after a cargo stoppage signal has been given by the ship.
ix) Terminal requirements/procedures for shifting ship.
x) Local port restrictions, for example, bunkering and deballasting requirements etc.
Cargo trimming is a mandatory requirement for some cargoes, especially where there is a risk
of the cargo shifting or where liquefaction could take place. It is recommended the cargo in
all holds be trimmed in an attempt to minimize the risk of cargo shift.
The ship's Master should be aware of the harmful effects of corrosive and high temperature
cargoes and any special cargo transportation requirements. Ship Masters, deck officers,
charterers and stevedores should be familiar with the relevant IMO Codes (for example, the
IMO Code of Safe Practice for Solid Bulk Cargoes, the IMO Code of Practice for the Safe
Loading and Unloading of Dry Bulk Carriers and the SOLAS Convention).
Devising a Cargo Stowage Plan and Loading/Unloading Plan
Exceeding the permissible limits specified in the ship's approved loading manual will lead to
over-stressing of the ship's structure and may result in catastrophic failure of the hull
structure. The amount and type of cargo to be transported and the intended voyage will
dictate the proposed departure cargo and/or ballast stowage plan. The officer in charge should
always refer to the loading manual to ascertain an appropriate cargo load distribution,
satisfying the imposed limits on structural loading.
1) There are two stages in the development of a safe plan for cargo loading or unloading:
a) Step 1: Given the intended voyage, the amount of cargo and/or water ballast to be carried
and imposed structural and operational limits, devise a safe departure condition, known as the
stowage plan.
b) Step 2: Given the arrival condition of the ship and knowing the departure condition
(stowage plan) to be attained, devise a safe loading or unloading plan that satisfies the
imposed structural and operational limits.
2) In the event that the cargo needs to be distributed differently from that described in
the ship's loading manual, stress and displacement calculations are always to be
carried out to ascertain, for any part of the intended voyage, that:
a) The still water shear forces and bending moments along the ship's length are within the
permissible Seagoing limits.
b) If applicable, the weight of cargo in each hold, and, when block loading is adopted, the
weights of cargo in two successive holds are within the allowable Seagoing limits for the
draught of the ship. These weights include the amount of water ballast carried in the hopper
and double bottom tanks in way of the hold(s).
c) The load limit on the tanktop and other relevant limits, if applicable, on local loading are
not exceeded.
3) The consumption of ship's bunkers during the voyage should be taken into account
when carrying out these stress and displacement calculations.
4) Whilst deriving a plan for cargo operations, the officer in charge must consider the
ballasting operation to ensure:
ii) The amount of water ballast and the corresponding tank/hold number(s) to be
discharged/loaded.
iii) The ship's draughts and trim at the completion of each step in the cargo operation.
iv) The calculated value of the still water shear forces and bending moments at the
completion of each step in the cargo operation.
v) Estimated time for completion of each step in the cargo operation.
vi) Assumed rate(s) of loading and unloading equipment.
vii) Assumed ballasting rate(s)
The loading/unloading plan should indicate any allowances for cargo stoppage (which may
be necessary to allow the ship to deballast when the loading rate is high), shifting ship,
bunkering, draught checks and cargo trimming.
The loading or unloading plan should only be changed when a revised plan has been
prepared, accepted and signed by both parties. Loading plans should be kept by the ship and
terminal for a period of six months.
A copy of the agreed loading or unloading plan and any subsequent amendments to it should
be lodged with the appropriate authority of the port State.
The more commonly adopted cargo distributions are:
TYPES OF CARGO
Dry bulk cargo is shipped in large quantities and can be easily stowed in a single hold with
little risk of cargo damage. Dry bulk cargo is generally categorized as either major bulk or
minor bulk.
Major Bulk Cargo
Major bulk cargo constitutes the vast majority of dry bulk cargo by weight, and includes,
among other things, iron ore, coal and grain. The major bulk cargos and its specific gravity
are as follows:
Specific
Type of cargo
Sub Categories
Density
Gravity
400
2400
2.1-2.9
0.4
2.4
dry
Iron sulphate - pickling tank -
1200
1.2
wet
1290
1.29
2) Coal
Charcoal
Coal, Anthracite, solid
Coal, Anthracite, broken
Coal, Bituminous, solid
Coal, Bituminous, broken
208
1506
1105
1346
833
0.208
1.506
1.105
1.346
0.833
3)Grains
Rice, hulled
Rice, rough
Rice grits
753
577
689
0.753
0.577
0.689
Wheat
Wheat, cracked
Buckwheat
769
673
657
780-
0.769
0.673
0.657
Grain - Wheat
Flour, wheat
800
593
0.78-0.8
0.593
Sugar, brown
Sugar, powdered
Sugar, granulated
Sugar, raw cane
Sugar beet pulp, dry
Sugar beet pulp, wet
Sugarcane
721
801
849
961
208
561
272
0.721
0.801
0.849
0.961
0.208
0.561
0.272
721
721
673
0.721
0.721
0.673
Barley
Grain - Barley
609
600
0.609
0.6
Oats
Oats, rolled
432
304
0.432
0.304
Rye
705
0.705
753
0.753
4) coarse Grains
2900
Specific
Type of cargo
Sub Categories
1)cement
Cement - clinker
Cement, Portland
Cement, mortar
Cement, slurry
2)Forest Products
Wood
Wood chips - dry
Afromosia
Apple
Ash, black
Ash, white
Aspen
Balsa
Bamboo
Birch (British)
Cedar, red
Cypress
Douglas Fir
Ebony
Elm ( English )
Elm ( Wych )
Elm ( Rock )
Iroko
Larch
Lignum Vitae
Mahogany ( Honduras )
Mahogany ( African )
Maple
Oak
Pine ( Oregon )
Pine ( Parana )
Pine ( Canadian )
Pine ( Red )
Redwood ( American )
Density
Gravity
1290-1540
1506
2162
1442
1.29-1.54
1.506
2.162
1.442
240- 520
705
660 - 830
540
670
420
170
300 - 400
670
380
510
530
960 - 1120
600
690
815
655
590
1280 - 1370
545
495 - 850
755
590 - 930
530
560
350 - 560
370 - 660
450
0.24-0.52
0.705
0.66-0.83
0.54
0.67
0.42
0.17
0.3-0.4
0.67
0.38
0.51
0.53
0.96-1.12
0.6
0.69
0.815
0.655
0.59
1.28-1.37
0.545
0.495-0.85
0.755
0.59-0.93
0.53
0.56
0.35-0.56
0.37-0.66
0.45
3)Agricultural Products
4)Mineral Concentrates
Redwood ( European )
Spruce ( Canadian )
Spruce ( Sitka )
Sycamore
Teak
Willow
Cottonwood
Coffee
Coffee, fresh beans
Coffee, roast beans
cotton
Cottonseed, dry, de-linted
Cottonseed, dry, not de-linted
Cottonseed, cake, lumpy
Cottonseed, hulls
Cottonseed, meal
Cottonseed, meats
Oil seeds
Oil cake
Oil, linseed
Linseed, whole
Linseed, meal
Bauxite, crushed
Alumina
copper
Copper ore
Copper sulphate, ground
510
450
450
590
630 - 720
420
416
0.51
0.45
0.45
0.59
0.63-0.72
0.42
0.416
561
432
0.561
0.432
561
320
673
192
593
641
0.561
0.32
0.673
0.192
0.593
0.641
785
942
753
513
1281
961
8930
1940-2590
3604
0.785
0.942
0.753
0.513
1.281
0.961
8.93
1.94-2.59
3.604
11340
11389
3684
4085
11.34
11.389
3.684
4.085
zinc
zinc oxide
7135
400
7.135
0.4
5046
3284
5.046
3.284
Limonite, solid
Limonite, broken
Limestone, solid
Limestone, broken
Limestone, pulverized
3796
2467
2611
1554
1394
3.796
2.467
2.611
1.554
1.394
2400 - 5015
2.4-5.015
lead
Lead, rolled
Lead, red
Lead, white pigment
5)]Steel Products
steel - rolled
steel - stainless
6)Agricultural Supplies
Phosphate
Gypsum, solid
Gypsum, broken
Gypsum, crushed
Gypsum, pulverized
7)Commercial Products
Potash
urea
wool
leather
7850
7480 - 8000
7.85
7.48-8
1762
2787
1290-1600
1602
1121
1.762
2.787
1.29-1.6
1.602
1.121
1281
735-785
1314
945
1.281
0.735-0.785
1.314
0.945
ANGLE OF REPOSE:The angle of repose or the critical angle of repose, of a granular material is the steepest
angle of descent or dip of the slope relative to the horizontal plane when material on the slope
face is on the verge of sliding. This angle is in the range 090.
Type of Cargo
Iron ore - crushed
Iron sulphate - dry
Iron sulphate - wet
Charcoal
Coal, Anthracite, broken
Coal, Bituminous, broken
Rice, hulled
Cement - clinker
Cement, Portland
Cottonseed, cake, lumpy
Cottonseed, meal
Cottonseed, meats
Oil cake
Phosphate
Gypsum, broken
Angle of Repose
35
30-44
30-44
35
27
35
30-44
75-85
30-44
30-44
35
30-44
45
25-29
40
STOWAGE FACTOR:In shipping, the stowage factor indicates how many cubic metres of space one metric tonne
(or cubic feet of space one long ton) of a particular type of cargo occupies in a hold of a cargo
ship. It is calculated as the ratio of the stowage space required under normal conditions,
including the stowage losses caused by the means of transportation and packaging, to the
weight of the cargo.The stowage factor can be used in ship design and as a reference to
evaluate the efficiency of use of the cargo space on a ship.
12-15
0.34 0.42
3-2.42
Coal
42-48
1.2-1.36
0.85-0.75
Grain heavy
42-56
1.2-1.42
0.85-0.72
Grain light
55-60
1.56-1.7
0.65-0.6
Bauxite
28-35
0.79-0.99
1.29-1.03
Phosphate/rock
33-34
0.91-0.96
1.12-1.06
General
24-29
0.69-0.82
1.47-1.24