Becker Marine Brings ‘Cross Over Rudder’ Innovation

By developing the „Cross Over Rudder“ the world leader in ship rudders, Becker Marine Systems, has again contributed in increasing energy efficiency in the shipping industry.

Environmental protection and energy efficiency are often associated with significant cost savings in the shipping industry. With the „Cross Over Rudder“ Becker Marine Systems has developed a product that allows further energy savings on the ship‘s rudder. The demand for this technical innovation is growing rapidly.

The inflow here is mostly unfavourable, but the resulting swirl can be converted into driving power by the new high-tech rudder. This optimization between the propeller hub cap and rudder is performed by a rudder bulb, making it the most energy-efficient solution with continued optimum manoeuvrability.

Specifically designed for stern optimization, the “Cross Over Rudder” is addition to the two existing energy-saving devices represented by the Becker Mewis Duct® and Becker Twisted Fin®.

Dirk Lehmann, Managing Director of Becker Marine Systems, and Sales Manager Walter Bauer speaking in an interview about the “Cross Over Rudder”:

What benefits does the “Cross Over Rudder” provide?

Dirk Lehmann: Our customers have realized that a great deal of energy can already be saved in front of the propeller through the use of the Becker Mewis Duct® and Becker Twisted Fin®. This is now possible on the rudder, too. If the three systems of the stern, propeller and rudder unit are perfectly matched with one another, energy consumption can be lowered in a double-digit percentage range.

Walther Bauer: We are working together with all leading model research institutes across the world to further improve efficiency below the waterline. We perform approximately 100 model tests every year and have gained a lot of valuable experience in this area. Becker Marine Systems is thus always able to offer a neutral position of expertise in regard to the optimization of propulsion and manoeuvring systems.

What role does the future model for „green shipping“ play?

Lehmann: We are actively working on it, because hydrodynamic energy conservation plays a prominent role in our products. Thanks to flow simulations using Computational Fluid Dynamics (CFD) complete ships including cargo, propeller design and rudder can be calculated. Becker Marine Systems is able to optimize the propeller and rudder part of this. Consequently, for shipyards and ship owners we are a competent partner for ship conversions as well as newbuildings.

Are shipping companies taking advantage of the cost savings?

Bauer: Only in part, because some shipping companies continue to buy just a rudder and not take the overall system into consideration. Substatial percentages of efficiency are still being lost here. Also, propellers are often being sold without performance optimization. This is where the opportunity to save money while protecting the environment is being squandered.

Lehmann: Becker Marine Systems can perform an overall optimization of the propeller hub cap and rudder bulb. This optimization is independent from the propeller manufacturer. Through our close collaboration with leading engine manufacturers such as MAN and Wärtsilä we are able to design complete drive propulsion systems along with manoeuvring systems. For both companies we have also developed a rudder matching their specific propeller.

For what kinds of ships is the „Cross Over Rudder“ particularly worthwhile?

Bauer: Primarily fast ships with a high propeller loads, such as ferries, container and passenger ships benefit greatly. The cost savings are so huge that the return on investment is usually achieved within one year. A retrofitting is often worthwhile as well. If ships have completely changed their operations profile for example, it may also be necessary to rebuild the propellers.

Lehmann: In such retrofitting solutions we offer to perform a CFD analysis of the rudder and propeller, which can then be adjusted accordingly. Unlike our competitors, we can perform these optimizations for each shipping company and shipyard independently from the propeller manufacturer.

What kinds of ships is Becker Marine Systems currently equipping with high-performance rudders?

Bauer: We have several notable orders, for example, five 14,000 TEU container ships at the Hyundai Heavy Industries (HHI) shipyard in South Korea and also five 18,800 TEU container ships for the United Arab Shipping Company (UASC). And then there are seven 8,800 TEU container ships for China International Marine Containers (CIMC) at Dalian Shipbuilding that are being chartered by the Mediterranean Shipping Company (MSC). In cooperation with Wärtsilä we are also involved with the new ConRo ships for the Grimaldi Group.

Lehmann: The Cross Over Rudder systems are in such high demand that they may take a 20 to 30 per cent share of incoming orders in the coming years. They could thus become a product similarly successful as the Mewis Duct, 580 units of which we have already sold. The resonance from ship owners continues to be very positive – and more than 530,000 tonnes of CO2 could be reduced overall.

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Becker Marine Systems, March 26, 2014