Malcolm Mclean was an American truck driver who invented container shipping and revolutionized the logistics industry. (Source: Will Box)

Now, at the onset of the Fourth Industrial Revolution, container shipping is undergoing a smart makeover to become more efficient, environmentally friendly and cost-effective. Major shipping companies and ports around the world are adopting smart technologies such as Blockchain, Big Data and IoT to automate operations. For example, the world’s largest container shipping company, Maersk is operating on IBM’s  blockchain-like system to cut out additional paperwork and conduct efficient, transparent operations. Major ports now have smart sensors and artificial intelligence (AI) to collect data about the environment and respond to changes in real-time. Finally, to keep up with all the new technology, new infrastructure is outfitting the smart ports of tomorrow.

So, here’s a glimpse into some of the most advanced ports around the world and what the future of container shipping holds.

SEE ALSO: The Changing Waves of the Shipping Industry

Port of Rotterdam

The Port of Rotterdam is Europe’s largest port with more than 461 million tons of cargo and 140,000 vessels passing through it every year. In January 2018, the Port of Rotterdam Authority and IBM announced they will collaborate on a digital transformation project to turn the Port of Rotterdam into a smart, connected port of the future. Already, there are sensors being applied across the span of 42 kilometers of the port both on land and in the sea to collect data about the port’s surroundings.

The Port of Rotterdam is the largest port in Europe and on route to becoming a smart, connected port. (Source: Port of Rotterdam)

Most importantly, the new port will have a central dashboard which will act as the brain of the entire port. The sensors will collect data and send it to the central dashboard where it will be processed in real-time via IBM’s IoT technology. Compared to the traditional radio communications among operators, the new system will drastically cut down the time it takes to communicate and manage traffic as well as prevent or respond to accidents. Operators will be able to oversee all operations of the port at once, and the new, efficient process is projected to save shipping companies up to an hour in berthing time, which translates to a cost savings of about USD 80,000 per hour.

Port of San Diego

The entire city of San Diego has been working to become a smart city and a leader in the movement towards net-zero energy consumption. The city’s port is no different. In 2013, it adopted the Climate Action Plan (CAP) under which the port has pledged to reduce greenhouse gas emissions by 10 percent by 2020 and 25 percent by 2035.

The Port of San Diego uses smart technology to reduce its carbon footprint. (Source: Cleantech San Diego)

As such, the city worked with various software companies led by Cleantech San Diego to develop a smart building project. The project’s smart technology uses sensors, Big Data and IoT to monitor energy levels across the city and provides real-time data upon which places like the city’s port can operate. Essentially, the data allows port operators to identify patterns in energy consumption as well as abnormalities to respond to in real time.

This year, the Port of San Diego and the state of California will undergo a USD 24 million modernization project with the goal of implementing zero-emission freight equipment over the next 20 years, and further incorporate smart technologies to reduce pollution.

SEE ALSO: Clear Skies Ahead: Clean Fuel for Green Shipping

Port of Singapore

Singapore is the trade hub of Asia and home to one of the busiest ports in the world. Every year, 130,000 cargo ships pass through its waters, but the number looks to increase with the growth of the e-commerce industry.

The Port of Singapore is en route to becoming one of the smartest ports in the world. (Source: Singapore Ministry of Transport)

Starting last September, the Maritime and Port Authority of Singapore (MPA) and IBM jointly implemented Project SAFER (sense-making analytics for maritime event recognition) to the port of Singapore. SAFER consists of new technologies to automate port operations, manage traffic and optimize the use of the port’s resources. With the new automation technology, the port can now enforce regulations automatically and monitor all vessel movements within the port at once in real time. Not only that, SAFER makes maritime operations much safer for operators and employees on the docks with the help of AI sensors for accident prevention. For continued development, the Maritime and Port Authority of Singapore held the Smart Port Challenge 2017 to foster startups in developing next-generation technology for enhanced and sustainable maritime operations.

As the ports mentioned above show, the global cargo shipping industry is headed towards vast change. New technologies such as blockchain, IoT and AI will greatly enhance transportation and handling efficiency and lead to greener practices. Traditional steel containers, on the other hand, will continue to be used in immense volumes for its 100 percent recyclability, lightweight and high-strength properties.

Watch hundreds of steel cans being produced at a Soudronic canning factory.

Advantages of Steel Packaging

Steel is one of the most commonly used packaging materials by manufacturers, because it is widely available, cost-effective and easy to work with. Steel packages can be customized to just about any shape and size depending on the needs of the business, and the continuously improving quality of steel lets manufacturers use less material without losing rigidity.

Steel as a packaging material is tamper-resistant, durable and has an extremely long shelf life, hence the reason why canned food seems to last forever. At the end of its life cycle, steel is 100 percent recyclable and does not lose any of its properties or qualities in the process. Plus, at least 25 percent of every steel can must be made of recycled steel, and its magnetic properties make it even easier to recover for recycling.

Steel is 100 percent recyclable and the most-recycled material in the world. (Source: Causeway Coast and Glens)

According to the Association of European Producers of Steel for Packaging (APEAL), steel packages are the most recycled packages out of all packaging materials, and its recycling rates keep climbing. In Europe, over 77 percent of steel packages are recycled and in countries such as the Netherlands, Belgium and Germany, rates exceed 90 percent.

New Innovations

Today, there are numerous new technologies taking steel packaging to a whole new level. Higher-quality alloys of steel and innovative new methods for processing steel are making everyday products safer, more convenient and efficient. Here’s some examples to show the advances being made in steel packaging.

Bacteria-free stainless steel surfaces

Researchers at Georgia Institute of Technology recently invented a new way to fight harmful bacteria such as E. coli on steel surfaces. Instead of the traditional antibiotics that are temporary and can aid bacteria in developing resistance, this new process uses an electrochemical etching chemical process to create thousands of tiny nano spikes on stainless steel surfaces. By switching up the levels of voltage and current flow in the electrochemical process, the researchers ended up with a rougher, “spiked” surface.

The spikes are about 25 nanometers long, and will kill both gram-positive and gram-negative bacteria on contact, without damaging human cells. The human eye cannot tell the difference between nanotextured steel and regular steel, and the technology increases corrosion resistance as well.

Nanotextured steel can kill bacterial upon contact without harming human cells. (Source: The Engineer)

Though the technology is new and is awaiting additional tests, it could be a permanent solution to treating bacteria and potentially change the medical and food industries completely. Nanotextured stainless steel can be used not only for packaging, but the manufacturing equipment that come in to contact with food. Researchers are also working to apply the technology to spine implants and other implants that come in direct contact with the body.

The world’s lightest 3-piece aerosol can

German company Henkel and packaging manufacturer Ardagh Group developed a new, sustainable aerosol spray can for Henkel’s beauty products using high-quality steel. The can is a mere 0.13mm thick, using up 15 percent less materials than its counterparts, but is also more rigid. The world’s lightest aerosol can also reduce C02 output by 3500 metric tons and water consumption by 900,000 cubic meters per year.

High-quality steel makes this aerosol eco-friendly. (Source: Pack World)

The development is in line with Henkel’s efforts to contribute to a circular economy. Thus the company aimed to design a packaging material that is not only effective and sustainable to produce, but is also 100 percent recyclable.

As the most recycled packaging material in the world, steel will continue to package food, beauty products, paints, chemicals and more manufactured goods. Especially with advances in the quality of steel alloys and innovative ways to process steel, manufacturers can be assured their products will be safe and sound in effective, cost-efficient, sustainable and safe packages.

Last year, California experienced the worst wildfires to date. (Source: Live Science)

It wasn’t just wildfires. The fire that broke out in Grenfell Tower in West London last June claimed 71 lives and sparked a public outcry for stricter building regulations around fire safety. The material used as cladding to wrap the outer part of the building came under scrutiny as it was extremely flammable and contributed to the rapid spread of the flames.

To prevent further disasters, architects, builders and policymakers need to reexamine the materials that go into building people’s homes, workplaces and public facilities.

Materials Matter

Steel is one of the most popular materials for construction as it is 100 percent recyclable, cost-effective and easy to work with. Moreover, World Steel Association’s Steel Construction Fact Sheet shows that steel is the most-researched and best-understood construction material available today. Its inherent characteristics and widely-available reinforcement options make steel the safest construction material for fire resistance.

eel is one of the strongest construction materials under high heat. (Source: CIC)

Fire resistance refers to the duration of time a building can withstand the load of the building, limit the passage of flames and gases and insulate the building against rising temperatures during a fire.

Steel is considered to be a fire-resistant material because it can retain all of its strength in temperatures up to 370ºC (700ºF). At 500ºC (930ºF), it loses 30 percent of its strength and at temperatures above 538ºC (1000ºF), unprotected steel loses close to half of its strength.

To put things into perspective, aluminum starts to decrease in strength when temperatures rise above 100ºC (212ºF), and at 204ºC (400ºF), aluminum loses 60 percent of its strength. Copper also loses 25 percent of its strength at 204ºC (400ºF).

Putting Materials to the Test

Darchem Engineering conducted the first-ever fire-resistance test in 1990 comparing galvanized steel, stainless steel, aluminum and fiberglass. Each material was exposed to temperatures from 1000 to 1050ºC (1832 to 1922ºF) for a period of 5 minutes. Both types of steel passed with minimal damage, while aluminum collapsed after 26 seconds, and fiberglass collapsed almost immediately.

Fire-resistance tests show that stainless steel is one of the most fire-resistant materials available. (Source: Applus)

They also conducted a 2-hour test with the same materials exposed to temperatures from 552 to 555ºC (1026 to 1032ºF). For stainless steel, the testing time was extended to 3 hours and it still had the least amount of damage out of all the materials. Galvanized steel passed the 2-hour mark, but did produce some molten zinc. Aluminum failed after 12 minutes, while fiberglass gave out in 6 minutes.

The results showed that steel, especially stainless steel, is the most fire-resistant material. However, one can never be safe enough when it comes to fire safety, and there are several ways to increase the fire resistance of steel that fall into 3 major categories.

Passive Fire Protection

Passive fire protection methods include boards, sprays and films that insulate the steel surface or structure against high temperatures. Fire protection boards are the most common type of passive fire protection as they can be customized and designed to fit the interior of the building. However, they are quite labor-intensive and costly compared to other options.

Boards are the most common types of passive fire protection. (Source: IPCOM)

Active Fire Protection

Active fire protection refers to any automatic or manual measure that can be taken to detect or fight fires. These include water sprinkler systems, alarms, smoke detectors, first responders and more. With advancements in AI and smart sensors, active fire protection will see vast improvements in the years to come and software systems will likely play a great role in fire prevention and protection.

The majority of active fire protection measures will become automated. (Source: Frontier Fire)

Intumescent fire protection

Intumescent fire protection includes paint-like substances that swell up in high temperatures and act as insulation against the heat. Typically, the intumescent substance will become 50 times thicker than its original state at about 200-250°C, well before steel undergoes any structural damage. Recently, intumescent paints have become much more prominent than passive types of fire protection as they are cost-effective, and can be applied on and off-site saving builders time and money.

Most recently, scientists and engineers from Nanyang Technological University (NTU) and national industrial developer JTC Corporation came up with a new intumescent fire protection paint called Firoshield. It is much cheaper than other types of intumescent paint and takes half the time to apply. The innovation will allow steel buildings to maintain its structural integrity for 2 hours with only 5 layers of paint, compared to the 15 layers required by other paints. 

Such innovations are expected to reinforce the safety of steel buildings, giving people more time for evacuation and limiting the spread of smoke and flames. On a final note, the fire-resistant qualities of steel should be taken into consideration not only for building frames and exteriors, but also for staircases, doors and other parts of a building that must stay intact for safe evacuations as well as for the safety of first responders.

On December 7, employees celebrated reaching 20 million tons and took a commemorative photo.

FINEX is an innovative, paradigm-shifting technology where molten iron is produced directly in a blast furnace. The process eliminates preliminary processing and uses cheaper powder-type iron ore and bituminous coal as raw materials. Subsequently, investment and production costs can be reduced by 85 percent compared to those of general blast furnaces of the same size. In addition, the technology reduces SOx and NOx emissions by 40 and 15 percent respectively, and fine dust particles can be reduced by 34 percent compared to general blast furnaces.

The beginnings of the technology date back to the 1990s when the Korean government chose POSCO’s smelting reduction steelmaking for a national project and contributed KRW 22.2 billion for research and development.

As a result, POSCO started operating the FINEX 2 plant with an annual production capacity of 1.5 million tons in 2007, and the FINEX 3 plant with an annual production capacity of 2 million tons in 2014, which now produces 10,000 tons of molten iron every day. Surprisingly, the Korean steel industry, which was heavily reliant on foreign technologies in 1968, now leads the world’s steel industry in terms of technology.

However, the path to success was filled with challenges.

In 1998, objections were raised against additional investment for the FINEX technology because there were no clear, tangible results even after KRW 60 billion was invested. Even so, POSCO management made a decision to construct a demo-plant with an additional investment of KRW 100 billion for technology development in order to secure long-term competitiveness rather than seeking immediate profit.   

In addition, POSCO convinced steelmaker Voestalpine, who was in possession of the world’s leading technology for molten iron production, to participate in the project as a partner. POSCO was able to do this by offering to cover the full cost of dispatched researchers and engineers should the technology become successful.

In 2003, there was a slight setback when the newly-opened core FINEX processing facility failed to operate successfully. However, after dozens of tests with 80 in-house professionals over 3 months, the facility was up and running.

Molten iron is produced directly in a furnace in the FINEX plant.

Sang-ho Lee, Director in Charge of Commercialization at POIST, said, “With less than 50 years of steelmaking experience, POSCO has managed to achieve a next-generation, innovative steel-producing technology. It feels great because even though POSCO started as a fast follower of foreign technologies, we are now a leading company in the world’s steel industry with our FINEX technology.”

POSCO currently has over 200 patents for its FINEX technology and HCI technology in Korea and 50 patents in more than 20 countries worldwide. Many overseas companies have expressed an interest in FINEX, and POSCO is in talks with world-renowned steelmakers in China to export its FINEX technology.

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