Japan’s Efforts on Ship Recycling Issues
Yasuhiro Urano
Manager of Regulations Unit / Chief Researcher Japan Ship Technology Research Association (JSTRA) (MSEA - Class of 2012, WMU) 9 April 2013 - SHIPREC2013
Contents Introduction Current condition of the industry Japan’s efforts for the reformation of the industry Conclusion
Introduction Ship Recycling = environmentally friendly…? Major ship recycling countries (97% of total): Bangladesh,
China, India, Pakistan, Turkey
Beaching method …environmental risks
Issues on occupational safety and health Basel Convention, 1989 Hong Kong Convention, 2009
Current condition of the industry Potential Hazards of Ships - Asbestos - Lead and other heavy metals - Organic tin compounds like TBT - Toxic and persistent organic compounds such as PCBs
Current condition of the industry Issues on Occupational Safety and Health - Insufficient training & human resources - Inappropriate or no PPE (personal protective equipment) - Exposure to explosion, fire, slip/drop, suffocation, falling steel plates Ø Some improvements can be seen recently… but problems still exist.
Several years ago
Recent pictures (Shameem, 2012)
Current condition of the industry Environmental Risks Land and marine pollution - Residual oil, heavy metals, TBT, PCBs Air pollution - Burned toxic chemicals (such as TBT, PCBs) - Ozone-depleting substances (such as HCFCs)
Current condition of the industry Causes of substandard operations - Cheap labor costs (minimize costs & maximize profits) - Lack of regulations or limitation of their enforcement - No liability for any damage by ship recycling activities
Local efforts - i.e. Bangladesh: Ship Breaking and Recycling Rules (Dec 2011) - i.e. India: Industrial Code (2013), Supreme Court Order (2007), GMB Ship Recycling Regulations (2003), Training development
Japan’s efforts for the reformation of the industry Why is Japan relevant to ship recycling issues?
- Merchant fleet
Source: UNCTAD
Japan’s efforts for the reformation of the industry Why is Japan relevant to ship recycling issues?
- Shipbuilding
Source: IHS Fairplay
Japan’s efforts for the reformation of the industry Why is Japan relevant to ship recycling issues? - Ship Recycling issues… ships’ entire lifetime - Japan is a key player in all phases leading to recycling phase
Highly responsible for addressing the issues related to recycling phase!
Japan’s principle efforts Entry into force of the HKC
Short-‐term efforts Class Society
Prepare national enforcement (Legislation / IHM control system)
-IHM management software (ClassNK) -IHM development practice (ClassNK, JSTRA, etc.)
Government
Support existing recycling yards in Japan and foreign countries
-Alang & Sosiya, India (Government)
Support
Three Principles:
Develop a new ship recycling method
-Muroran project (NPO “Ship Recycle Muroran”) -Research on technologies to enhance SR (Government, JSTRA, JMS, etc.)
1. Multi-stakeholders involvement Medium-‐ / long-‐term efforts 2. National and international cooperation 3. Short-term and long-term efforts
Shipbuilding & Ship Machinery
Collaborate
Popularize the new method for ship recycling in Japan and globe
Reduce
Reuse & Recycle Other Industries
Promote 3R: “Reduce” “Reuse” “Recycle” – Minimize hazardous materials in ships/ship machineries – Downsize ship machineries and reduce their weight – Design ship structures/equipment for easy disassembling – Control info on reusable and recyclable materials on board
Time
Support to recycling yards in India India Ship Recycle Project – as an ODA program - Reformation of existing ship recycle yards (Alang & Sosiya areas) - Establishment of a common facility for extracting hazardous materials (dry dock) - Construction of oil & waste treatment facility Now under the process to make an official request to the Japanese government
Sosiya Area abt 76 plots
Alang Area abt 96 plots
Oil & Waste Treatment Facility
Pilot Project Site with improvement in line with HKC’s requirements
O il T reatm ent
350m x 60m Dry Dock as Common Facility
Trial of a new ship recycling method in Japan: “Muroran Project” To seek a new ship recycling industry model in Japan… A pilot project was conducted by the Muroran Ship Recycling Study Group in 2010 (Muroran, Hokkaido) - PCC demolition experiment utilizing vacant port wharf - A new technology and advanced techniques - Research on recycling of steels - Cost analysis
Pure Car Carrier “New York Highway”
Muroran Project - Demolition Experiment Full satisfaction of the requirements of the Hong Kong
Convention to clear safety and health / environmental risks - IHM development and authorization (by ClassNK) - SRFP & SRP development - Afloat method - Properly trained and qualified workers - Safety management structure - Waste stream management
Muroran Project -A New Technology and Advanced Techniques Water-jet cutting machine
- newly developed!! (no fire generation for safety) Automatic cutter
(enhance work efficiency) Oxygen lance cutting
(enhance work efficiency) Saber saw cutting
(no fire generation for safety) Labounty shear cutting
(enhance work efficiency)
Muroran Project -A New Technology and Advanced Techniques Three-layer method
*specific to PCC demolition (enhance work efficiency)
Caisson dock
(pollution prevention)
Paint removal sheet
(pollution prevention)
Muroran Project -Research on recycling of steels Made cast irons and steels Tested the qualities of these materials As a result… Scrapped irons and steels are considered to be reusable as high value-added products
Muroran Project -Costs for the pilot project Costs for recycling 11,250 LDT (PCC):
390 million JPY for the pilot project (fixed case: 165 million JPY) Price of the ship: 243 million JPY Total sales (steels, equipment): 421 million JPY
Break-even point of total costs: 339 million JPY Ø About 20% decline in total sales will be manageable Ø Under the “low” ship price: 220 USD/LDT
(China and the Indian subcontinent: 400-500 USD/LDT)
Muroran Project -Further efforts to be continued… After the pilot project…
- Proposal 1: Give incentives to shipowners and stakeholders - Proposal 2: Reduce recycling costs - Proposal 3: Promote high value-added production Currently…
- Muroran Ship Recycling Study Group became a NPO named “Ship Recycle Muroran” in December 2012 - 5 sub-groups are separately proceeding the project based on the above proposals
3R: “Reduce” “Reuse” and “Recycle” These Japan’s efforts (IHM/Support to India/Muroran
project) belong to a larger plan of “3R” to be addressed on long-term basis. Reduce: Shipbuilders and suppliers should reduce hazardous materials included in their products and replace them with substitutable safe materials as much as possible. In parallel, the government is requested to develop certain systems to incentivize these actions. For effective use of resources, downsizing and weight reduction of ship machinery should be promoted conforming to the safety and environmental criteria. Reuse and Recycle: In order to efficiently reuse and recycle ship structures and equipment, they should be designed to make them easy to disassemble in consideration of work efficiency in the stages of disposal and recycling. As well as the case of the IHM, information on reusable and recyclable materials should be controlled to enable their efficient sorting in ship recycling yards.
Conclusion Early entry into force of the Hong Kong Convention is necessary
for the reformation of the whole industry. Some ship recycling yards still have safety and environmental
risks, even though there are significant efforts and reformations. Japan is responsibly and proudly trying to contribute to the
reformation of the industry (IHM control systems / HKC enforcement support / new ship recycling method).
Special thanks to: Mr. Yasuo Nakajo, Japan Marine Science Inc. Dr. Shimizu Kazumichi, Muroran Institute of Technology
Presented by Yasuhiro Urano E-mail to: urano@jstra.jp