(RTG) Cranes - TOC Container Supply Chain: Asia

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(RTG) Cranes - TOC Container Supply Chain: Asia

VYCON

RTG Crane Energy gy Storage g

System for Fuel Savings

Test Test Results

Results


RTG Crane Applications

• EEnergy storage t on RRubber bb Tired Ti d Gantry G t

(RTG) Cranes

– Reduces fuel consumption from diesel

generator by re re-using using power generated by

the container lowering cycle

– Reduces emissions by not requiring power

from the diesel generator for container lifts

– Can be installed to existing RTG cranes

– Can be ordered as part of new RTG cranes

– Allows for reduction in diesel generator set

size


Typical RTG Crane Power

OOperating ti Cycle C l

Graph shows typical RTG and AC hoist motor loads for both lifting & lowering

There is significant energy that is wasted


Reduced Fuel

Consumption

RTG Crane Operating Cycle with

EEnergy Storage St Technology

T h l

With REGEN

Without REGEN

• Reduced peak power

requirements

• Less fuel consumption

• RReduced d d NO NOx and dPM PM

emissions

• Allows for replacement

of conventional genset

to a reduced power

output genset


RTG Power Schematic with

EEnergy St Storage

Hoist Drive (Inverter)

DC

AC

AC

AC

DC

DC

Generator Set AC Hoist Motor

VYCON REGEN


VYCON REGEN

VYCON REGEN

YICT Test Results Summary


Test Plan

• Testing was conducted in a manner that each

stage g of the test would pprovide

valuable

information on the performance of the RTG

– Phase 1. Verify existing RTG fuel usage and

consumption under normal operating conditions.

– Phase 2. Test same RTG with REGEN system

under normal operating conditions

– Phase 3. Test RTG with REGEN and a reduced

output power generator set


• Phase 1 testing:

− Fuel baseline

− Conventional

RTG

− Normal day

operation

• Test Period:

– Baseline:

April 17 - 30, 2007

– Retrial:

July 6 - 20, 2007

Phase 1 Results

Item Meter YC83 YC99

YC99

(Retrial)

1 Engine Run Time (hours) 210.59 221.15 289.78

2 Number of Moves 1948 2243 3185

3 Hoist Run Time (hours) 63.51 70.70 100.54

4 Trolley y Run Time ( (hours) ) 28.85 36.50 47.9

5 Gantry Run Time (hours) 19.06 22.96 28.45

6 Fuel Consumption (liters) 4688 5359 7086

7

8

AAverage ffuel l consumption ti

per move (liters/move) 2.407 2.389 2.225

Average fuel consumption

per running hour (liters/hour)

22.261 24.232 24.453

9 Average moves/hour 925 9.25 10 10.14 14 10 10.99

99


Phase 2 Results

• Phase 2 testing:

• Test period: June 22 – July 66, 2007

− Fuel baseline with REGEN

− Conventional Genset

Item Description YC99

1 Engine Run Time (hours) 332.46

2 Number of Moves 4037

3 Hoist Run Time (hours) 128.51

4 Trolley Run Time (hours) 63.93

5 Gantry Run Time (hours) 40.13

6 Fuel Consumption (liters) 8234

7

8

Average fuel consumption

per move (lit (liters/move) / ) 2.040

Average fuel consumption per

running hour (liters/hour)

24.767

Item Description YC99

9 Real Energy (kWh) 15332.2

10 Reactive Energy (Kvar) 6181.3

11 Total Load Lifted (tons) 38032.0

12 Average Load Lifted (tons) 9.42

13 Energy per Lift (kWh) 3.80

14 Energy per Ton Lift (kWh) 0.403

15 Average moves/hour 12.14


• Phase 3 testing:

− Reduced Power Output Genset & REGEN

Item Description YC99

1 Engine Run Time (hours) 137

2 Number of Moves 1809

3 Hoist Run Time (hours) 56.94

4 Trolley Run Time (hours) 27.42

5 Gantry Run Time (hours) 16.12

6 Fuel Consumption (liters) 2713

7

8

Average fuel consumption

per move (liters/move)

Phase 3 Results

(lit / ) 11.500 500

Average fuel consumption per

running hour (liters/hour)

19.803

• Test period: August 17 – 23 23, 2007

Item Description YC99

9 Real Energy (kWh) 6094.7

10 Reactive Energy (Kvar) 2326.1

11 Total Load Lifted (tons) 18410.3

12 Average Load Lifted (tons) 10.18

13 Energy per Lift (kWh) 3.369

14 Energy per Ton Lift (kWh) 0.331

15 Average moves/hour 13.20


YICT Test Results Summary

Phase Genset Configuration Crane No. REGEN

1A

Detroit Diesel Model

6063HK35

1B

Detroit Diesel Model

(Retrial) 6063HK35 (Retest)

1C

2

Detroit Diesel Model

6063HK35

Detroit Diesel Model

6063HK35

Mo Moves/ es/ Liters/

Hour

Move

YC99 No 10.14 2.389

YC99 No 10.99 2.225

YC83 No 9.25 2.407

YC99 Yes 12.14 2.040

3 MAN Model D2866LE201 YC99 Yes 13.20 1.500

Phase 1A 1B 1C

2

REGEN only

14.61% 8.31% 15.25%

3

REGEN With New 37.21% 32.58% 37.68%

Engine


Flywheel Energy Storage

• A flywheel is a mechanical battery

• Stores energy by increasing the

rotational t ti l speed d of f a mass

• Discharges the energy by using the

stored energy in rotating mass to

produce output power

• Produces high power output for short

durations (1 – 30 seconds)

• Can be utilized in a variety of

y

applications


Flywheel System


Fuel

Savings

• Up to15% fuel

savings with the

REGEN system

• Up to 38% in

fuel savings with

a smaller genset

Overall REGEN Benefits

Net Emissions

Reduction

• 95% reduction of

Particulate Matter

(PM) during lift

cycles

• 35% reduction of

PM in the overall

cycle

• 30% reduction in

NO x

System

Response

• Immediate

acceleration

upon lift

command

REGEN

• Lowering

highly controlled

• Reduction of

container

loading cycle by

15%

Generator

Life

• Extending Life

• Reducing

maintenance

Noise

• Reduction of

acceleration noise

during each lift

Yard Benefits

• No additional land

required

• Retains mobility of

RTG cranes for

quick deployment

• Quick retrofit

• Minimal downtime


Conclusions

• Testing concludes that an energy storage system reduces fuel

consumption by up to 15% with a conventional genset on a RTG

operating at 10 moves/hour

– Increase in moves/hour will improve the fuel savings

• Energy storage enables the use of a reduced output power genset

and fuel reductions of up to 38%

– Increased moves/hour will improve the fuel savings

• No productivity penalties with a reduced size diesel generator set

• With continued increase in fuel prices, energy storage must be a

standard component on every RTG crane to reduce overall

operating costs

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