The second one! Shanghai COSCO Shipping Heavy Industry Delivers Another Methanol-Dual-Fuel Converted Ship

On October 26, the second vessel of COSCO Shipping Lines' 20,000-TEU Constellation series, the "COSCO Shipping Gemini," completed its methanol dual-fuel retrofit at COSCO Shipping Heavy Industries in Shanghai and was officially delivered for sailing.

As another landmark project in the same series following the "COSCO Shipping Libra," this vessel builds on the successful experience of its predecessor while achieving comprehensive optimization and upgrades. The reduced turnaround time further underscores Shanghai COSCO Shipping Heavy Industries' proven expertise in green propulsion retrofits for large container ships, injecting sustained momentum into the shipping industry's transition toward low-carbon operations.

On July 26, the vessel "COSCO Shipping Gemini" docked at COSCO Shipping Heavy Industry in Shanghai. Prior to the ship's arrival, the project team systematically reviewed and analyzed the dismantling process, lifting plan, and proven construction methods used during the renovation of the vessel "COSCO Shipping Libra." Based on these insights, they optimized and refined the approach tailored specifically for the "COSCO Shipping Gemini." Drawing from the successful experience gained during the "COSCO Shipping Libra" transformation project, the team took the lead in fostering deep collaboration between engineering teams and operational departments, thoroughly refining and upgrading the entire dismantling plan. For critical stages of structural modification, the team adopted a synchronized construction approach using both 60-ton and 40-ton gantry cranes. This method significantly boosted dismantling and lifting efficiency compared to the single-equipment operation previously employed on the "COSCO Shipping Libra," thereby shortening the overall project timeline. Additionally, the dismantled old structures were processed off-site in phased batches, effectively maximizing the utilization of available space and creating favorable conditions for seamless coordination with subsequent construction activities.

The optimization efforts in the dock repair project have yielded particularly remarkable results. Drawing on the experience gained from the 136-hour dry-docking of the COSCO Shipping Libra, the project team proactively refined the on-dock construction plan, successfully reducing the duration of the on-dock work for the COSCO Shipping Gemini to just 96 hours. As a result, all on-dock tasks for the COSCO Shipping Gemini were completed in a single dry-docking cycle. Additionally, during the methanol dry compartment sealing operation, the team streamlined the workflow and shifted certain steps forward in the process, enabling them to complete the air-pressure procedure—previously scheduled for two days on the COSCO Shipping Libra—took only one day per session. This optimization further shortened the critical path schedule, enhancing overall efficiency.

During the core system renovation and debugging process, the vessel "COSCO Shipping Gemini" achieved several significant breakthroughs. Specifically targeting the critical task of applying specialized coatings to the methanol tanks and dry cargo holds, the project team systematically optimized the sandblasting procedure. By implementing a scientifically planned work schedule, the "COSCO Shipping Gemini" successfully carried out 24-hour coating operations, thereby saving four days from the overall project timeline.

During the commissioning and fueling phases, both efficiency and success rates were significantly improved. In the methanol-fueling process, the team continued to employ the "vehicle-plus-ship" combined approach while optimizing the operational procedures. As a result, the overall fueling time was reduced by 4 hours compared to the COSCO Shipping Tianbingzuo vessel—particularly, the ship-to-ship connection was successfully debugged on the first attempt, greatly minimizing operational risks. Meanwhile, during the power system commissioning, the auxiliary machinery startup was completed ahead of schedule relative to the COSCO Shipping Tianbingzuo, and the main engine trial run achieved full success at once, thoroughly validating the reliability and stability of the retrofit solution. These breakthroughs not only benefited from the team’s precise incorporation of insights gained from the first vessel built but also highlighted the project team’s ongoing commitment to innovation.

The smooth departure of the "COSCO Shipping Gemini" marks the entry of COSCO Shipping's 20,000 TEU Constellation series methanol dual-fuel retrofit project into a phase of scaled and standardized advancement. Through the retrofitting of two vessels, Shanghai COSCO Shipping Heavy Industry has already developed a mature, replicable template for converting large container ships to methanol dual-fuel operation. For instance, they have established standardized procedures covering methanol storage tank sandblasting and painting, as well as LFSS system commissioning—comprehensive workflows that include structural lifting, power upgrades, specialized coating applications, and fuel bunkering. Compared to the retrofit timeline of the first vessel, the "COSCO Shipping Libra," the "COSCO Shipping Gemini" completed its transformation 21 days faster. This efficient progress clearly demonstrates the significant scale benefits of the project’s standardized retrofit approach.

The successful delivery of the "COSCO Shipping Gemini" marks another milestone in Shanghai COSCO Shipping Heavy Industry's journey toward a low-carbon future, signaling a powerful new chapter in the company’s efforts to transform toward sustainability and environmental protection. The methanol dual-fuel retrofit project involves critical upgrades across multiple core systems— including the main engine, auxiliary engines, and fuel supply systems—presenting significant challenges along the way. This initiative not only represents an upgrade in Shanghai COSCO Shipping Heavy Industry’s ship repair and modification solutions but also underscores the company’s commitment to building a flagship facility dedicated to green, low-carbon, and smart shipbuilding and marine engineering repairs and modifications. Moving forward, Shanghai COSCO Shipping Heavy Industry will continue to embrace the spirit of "Upholding Integrity while Embracing Innovation, Fearlessly Pursuing Progress," using innovative solutions as its brush and collaborative development as its ink, to write a new chapter of high-quality, sustainable growth for the enterprise!