Royal Roos' sustainable engineering: How Odfjell and bound4blue are equipping a chemical tanker with eSails®

What does it take to install innovative wind propulsion technology on an existing ship? In conversation with Fulko Roos, Managing Director of Royal Roos, and his team members Zakaria Sacchi and Andrés López Veiga we discover how thorough engineering makes the difference in sustainable retrofits in the maritime sector.

The search for sustainable solutions

The maritime sector is increasingly looking for solutions to reduce CO2 emissions. This is leading to groundbreaking innovations. Last year, Odfjell announced that they would be the  second shipping company in the world to install suction sails (eSAIL®) on a chemical tanker, in collaboration with technology developer bound4blue.

Royal Roos was commissioned as the engineering partner to support this pioneering project. What does this involve? Read on to find out.

From feasibility study to installation: the complete process

For innovative, sustainable retrofits like this, everything begins with a feasibility study. Where can the sails, developed by bound4blue, best be placed? What technical obstacles need to be addressed? And equally important: how do we ensure safe integration with the existing systems on board?

"With projects like these, you always face challenges. To overcome this challenges and reach a successful, efficient and optimized integration of  eSAILs® on a vessel, two key things are needed: first is selecting the right partners with great expertise and second is ensuring a very close collaboration between the owner (Odfjell), the system supplier (bound4blue) and the integrator (Royal Roos)” says Fulko Roos, Managing Director of Royal Roos. "For instance, the ship has ATEX zones where explosive gas mixtures may be present. The collaboration between all parts made possible the safe installation of non-exproof  eSAILs® (with lower CAPEX) by identifying some available locations where to install them and with higher foundations ensuring safe positioning outside ATEX zones and with less disturbed wind to optimize performance."

Royal Roos has been involved with bound4blue from the beginning, investigating all possible configurations. "In the first phase of the project, based on input from bound4blue, we proposed five different configurations that would meet all rules and regulations," Zakaria explains. “Then, bound4blue performed and aerodynamic interference analysis of the proposed configurations, to identify which had the best performances”

"This allowed to identify the optimal and most efficient placement for the four eSAILs®. The best performing configuration required to relocate a tank that was previously positioned at the rear starboard sail location. Odfjell evaluated the extra gains in savings of the optimized configuration vs. the cost of relocating the tank concluding that this was the best option. Another example of the importance of close collaboration between all parts.

Royal Roos performed structural calculations, including fatigue analyses according to DNV standards.

Engineering as the key to successful integration

The real challenge in retrofits often lies in integration with existing ship systems. In this project, the planned position of the sails would obstruct the radar and navigation lights. We solved this in our engineering process. From control panels to lighting, everything had to be recalculated.

Royal Roos was involved not only in the technical aspects but also in the design. They also conducted 3D scans to determine the precise positioning of all components, ensuring no undesired surprises would appear at installation. Every detail was carefully worked out, from the foundations, to the stability calculations that are crucial for the safe operation of the ship after the retrofit. We also performed an extensive visibility analysis for all possible scenarios to reach an agreement with the classification societies, ensuring that the chosen integration complies with all rules and regulations.

"Electrical integration was another important aspect of the project," says Zakaria. "We were in direct contact with both bound4blue and Odfjell to ensure a simple and feasible integration. This also included the installation of a new camera system to meet visibility requirements."

Support during tenders

Zakaria: "What sets us apart is our complete service from start to finish. In addition to the technical engineering, we also helped Odfjell with preparing tender documentation for the installation of the steel work. We also provided input for the tender process for the final installation of the sails, which have been installed in Antwerp.

"As a technical coordinator of the integration, we also helped Odfjell streamline communication between all stakeholders," adds Andrés.

“This practical approach, where we provide a single point of contact for the complete process, ensures that the client can focus on their core activities while we coordinate all technical aspects."

Stability calculations and safety first

A crucial part of the project were the intact and damage stability calculations. The addition of sails to an existing ship impacts the stability and behavior of the vessel. Thankfully b4b eSAILs size is smaller than other WAPS options. Royal Roos performed detailed calculations to ensure that the ship could operate safely under all conditions.

We also assisted with the inclining test, which was requested on that project, essential steps to ensure the safety of the retrofit and obtain approval from classification societies. This specialized expertise underscores our position as a knowledge partner in complex maritime retrofits.

Flexibility as the key to success

"What customers like Odfjell and bound4blue appreciate in our approach is our flexibility, speed and willingness to find optimal solutions to the challenges," emphasizes Fulko. "With innovative projects like this, it's essential to be able to quickly adapt when new insights or challenges arise. Due to our efficient organization, we can respond immediately and implement solutions without little delay in the process."

"Besides the eSAILs® project, we were simultaneously working on two other projects for Odfjell," says Fulko. "We performed modifications to the chiller room and integrated a deck cargo heater, which highlights the versatility of our team."

This flexibility, combined with deep technical knowledge, makes Royal Roos an ideal partner for sustainable retrofits.

Growing expertise in sustainable retrofits

Fulko continues: "The collaboration with Odfjell and bound4blue represents an important milestone for Royal Roos in our growing portfolio of sustainable retrofits. The project has not only resulted in a groundbreaking innovation for the maritime sector but has also led to new assignments.

We are now starting work on Odfjell's sister ship, and bound4blue has asked us to apply our maritime engineering expertise to other projects. Additionally, Odfjell has recommended us to other shipping companies showing interest in similar sustainable solutions. We're very pleased about that."

The future of maritime retrofit projects

Royal Roos feels right at home with sustainable retrofits. "With increasingly stringent environmental requirements and the urgent need to reduce CO2 emissions in the maritime sector, we see a growing demand for our services.

What makes sustainable retrofits so interesting is that each assignment is unique," concludes Fulko. "There is no standard solution. Each ship, each technology, and each customer requires a tailored approach. And precisely that challenge fits perfectly with Royal Roos' DNA: flexible, approachable, and with deep technical expertise that makes the difference. We know what to expect - and that predictability in a complex process provides our customers with the certainty they need."

"This is truly a project that we at Royal Roos are extremely proud of," says Fulko Roos with visible enthusiasm. " It's great to see how our engineering expertise contributes to such a groundbreaking innovation in the maritime sector. And the best part is: this is just the beginning of what's possible with sustainable retrofits."

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