This also sets a standard for shipbuilding in the United States – the speed is a couple of years for the 4 of these ships. This is going to be tough for the Trump administration to get to this level of shipbuilding.
The world’s largest car carrier has left a yard in China on its maiden voyage to Brazil.
The 9,200 ceu BYD Shenzhen pips Höegh Autoliners’ Aurora class series by 100 cars in terms of capacity, and becomes the fourth vessel in Chinese auto manufacturer BYD’s growing fleet with another two ships set to start trading soon.
The 219 m long, LNG dual-fuel powered ship was constructed by China Merchants Jinling Ship
The shipbuilding process for a vessel like the BYD Shenzhen, a 9,200 CEU dual-fuel LNG Pure Car and Truck Carrier (PCTC) constructed by China Merchants Jinling Shipyard (Nanjing), involves multiple stages, from design to delivery. Below is a detailed overview of the shipbuilding process, tailored to the context of the BYD Shenzhen and similar PCTCs, based on available information and general shipbuilding practices.
1. Design and Planning
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Conceptual Design: The process begins with defining the ship’s purpose, capacity, and technical specifications. For the BYD Shenzhen, this included a 219.9-meter-long, 37.7-meter-wide PCTC with a 9,200 CEU capacity, dual-fuel LNG propulsion, and energy-saving features like battery hybrid systems and shaft generators.
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Detailed Design: Naval architects and engineers create detailed blueprints, including hull shape, deck layouts (16 decks for BYD Shenzhen), propulsion systems, and environmental compliance features (e.g., IMO Tier III for NOx emissions). The design incorporates BYD’s box battery packs and energy-saving devices.
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Regulatory Approval: The design is submitted for Approval in Principle (AiP) to classification societies like DNV, ensuring compliance with safety, environmental, and performance standards. For example, China Merchants Jinling received an AiP for a similar 11,000 CEU PCTC design.
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Contract Signing: BYD signed an order for four 9,200 CEU PCTCs with China Merchants Industry in 2022, with construction split between Nanjing and Jiangsu yards.
2. Pre-Construction Preparation
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Material Procurement: High-strength steel, LNG fuel tanks, propulsion systems, and specialized components (e.g., Atlantic Rudder with Asymmetric Rudder Technology from Damen Marine Components) are sourced.
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Yard Preparation: The shipyard, China Merchants Jinling (Nanjing), allocates space in its 1.23 million square meter facility, preparing dry docks or slipways for construction.
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Steel Cutting Ceremony: Construction officially starts with cutting the first steel plate, a ceremonial milestone. For the BYD Shenzhen, this occurred on March 29, 2024, marking the entry into the construction phase.
3. Hull Construction
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Block Fabrication: The hull is built in modular sections or “blocks” in the shipyard’s workshops. Each block, comprising steel plates and internal structures, is welded together. For PCTCs like BYD Shenzhen, blocks are designed to accommodate vehicle decks and LNG fuel systems.
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Keel Laying: The first block is placed in the dry dock or slipway, marking the start of hull assembly. Specific keel-laying dates for BYD Shenzhen are not documented, but this typically follows steel cutting by a few months.
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Block Assembly: Blocks are aligned, welded, and joined to form the complete hull. The BYD Shenzhen’s hull was optimized for energy efficiency, incorporating a stern flow optimization device and air lubrication system, as seen in similar designs by China Merchants.
4. Outfitting
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Structural Outfitting: Internal structures, such as the 16 vehicle decks, ramps, and compartments, are installed. PCTCs require precise deck spacing to maximize vehicle capacity (9,200 CEUs for BYD Shenzhen).
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Machinery Installation: The dual-fuel propulsion system, capable of running on LNG or conventional fuel oil, is installed, along with two C-type LNG storage tanks, shaft generators, and battery hybrid systems. The propulsion system meets IMO’s Energy Efficiency Design Index (EEDI) Phase 3 requirements.
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Systems Integration: Electrical, navigation, and environmental systems (e.g., thyristor selective catalytic reduction for denitrification) are installed. The BYD Shenzhen features drag-reducing anti-fouling hull coatings and shore power capability for enhanced efficiency.
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Rudder and Propeller: The ship is fitted with specialized rudders (e.g., Damen’s Atlantic Rudder with Silent Bulb) and propellers optimized for long-distance efficiency.
5. Testing and Trials
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Dry Testing: Systems like electrical, propulsion, and navigation are tested on land or in the dock to ensure functionality.
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Undocking: The completed hull is floated out of the dry dock, marking the end of major construction. For BYD Shenzhen, undocking occurred on January 15, 2025, indicating readiness for sea trials.
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Sea Trials: The ship undergoes rigorous testing at sea to verify speed (18.5–19 knots for BYD Shenzhen), maneuverability, fuel efficiency, and system performance. Any issues are addressed before final delivery.
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Environmental Testing: The LNG dual-fuel system and emissions controls are tested to ensure compliance with IMO standards for NOx, SOx, and CO2 reductions.
6. Finishing and Delivery
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Final Outfitting: Interior finishes, crew accommodations, and safety equipment (e.g., fire suppression systems for vehicle decks) are completed.
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Naming Ceremony: The ship is officially named, often with a public ceremony. The BYD Shenzhen’s naming and handover ceremony took place on April 22, 2025, in Jiangsu.
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Handover: The ship is delivered to the owner, BYD, after final inspections. Delivery of BYD Shenzhen occurred on April 22, 2025, approximately 13 months after steel cutting.
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Post-Delivery: The ship begins loading operations (e.g., BYD Shenzhen was set to load vehicles for Brazil) and enters commercial service.
Timeline for BYD Shenzhen
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Order Placed: 2022 (part of a four-ship order with China Merchants Industry).
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Steel Cutting: March 29, 2024.
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Undocking: January 15, 2025.
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Delivery and Naming: April 22, 2025.
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Total Construction Time: Approximately 13 months, consistent with the 12–18 month timeline for similar PCTCs.
Unique Features of BYD Shenzhen’s Construction
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LNG Dual-Fuel Technology: The integration of LNG storage tanks and dual-fuel engines required specialized engineering to balance fuel capacity with vehicle space.
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BYD Battery Packs: The ship is the first PCTC to use BYD’s marine box-type battery packs, likely for auxiliary power during docking or in low-emission zones.
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Environmental Focus: Features like boil-off gas recondensers, hybrid battery systems, and energy-saving devices reflect BYD’s emphasis on sustainability.
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Scale: As the world’s largest PCTC at delivery (9,200 CEUs), the ship required precise engineering to maximize capacity while maintaining efficiency.
Challenges in PCTC Construction
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Technical Complexity: PCTCs require lightweight yet strong structures to support multiple vehicle decks, with precise weight distribution to ensure stability.
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Environmental Compliance: Meeting IMO’s stringent emissions standards (EEDI Phase 3, NOx Tier III) demands advanced propulsion and exhaust treatment systems.
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Supply Chain: Sourcing specialized components, like LNG tanks and battery systems, can introduce delays, though China Merchants’ integrated facilities mitigate this.
China Merchants Jinling Shipyard’s Role
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Expertise: The Nanjing yard, with a 2 km shoreline and 2 million deadweight ton annual capacity, specializes in RoRo vessels and PCTCs, holding a leading global market share.
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Efficiency: The yard’s ability to deliver BYD Shenzhen in ~13 months reflects streamlined processes and experience with similar vessels (e.g., six dual-fuel PCTCs for Eastern Pacific Shipping).
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Innovation: The yard incorporates advanced technologies, such as Deltamarin’s hull optimization and energy-saving devices, as seen in related projects.
Sources and Further Research
The details above are compiled from web sources, including reports on BYD Shenzhen’s construction milestones and general shipbuilding practices. For more specific technical data, you could:
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Contact China Merchants Jinling Shipyard directly via their website (cmindustry.com.hk).
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Consult maritime databases like MarineTraffic or DNV’s vessel registry for detailed specifications.
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Review BYD’s official announcements for additional fleet details.
If you’d like me to focus on a specific phase (e.g., hull construction or sea trials), search for more sources, or provide a visual representation of the process (e.g., a timeline chart), please let me know!
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