GREENCRANES Final Info Days - Port of Valencia...FINAL INFORMATION DAY BRUXELLES, 15 MAY 2014 GREENCRANES Final Info Days First European LNG Dual Fuel Reach Stacker Prototype Global

FINAL INFORMATION DAY

BRUXELLES, 15 MAY 2014

GREENCRANES Final Info Days

First European LNG Dual Fuel Reach Stacker Prototype

Global Service S.r.l.

PERCRO Laboratory - Scuola Superiore Sant’Anna

Speaker: Andrea Papini

Consortium:

Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals

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26%

13%

10%

51%

Electrical Consumption 2011 (kWh)

STS Cranes Terminal Lightning Offices Reefer Containers

PORT OF LIVORNO – DARSENA TOSCANA

2011 (kWh)

STS Cranes 2.356.698

Terminal Lightning 1.229.174

Offices 923.628

Reefer Containers 4.633.337

Total Terminal TDT 9.151.837

28%

6%

23%

41%

2%

Yard Machinery. Total Fuel Consumption TDT 2011

RTGs Internal Tractors External Tractors Reach Stackers ForkLifts

PORT OF LIVORNO - DARSENA TOSCANA

Fuel Consumption 2011 (litres)

RTGs 380.850

Internal Tractors 85.979

External Tractors 308.180

Reach Stackers 552.203

Forklifts 21.359

Total Terminal TDT 1.348.571

ELECTRICAL CONSUMPTION FUEL CONSUMPTION

The choice of Reach Stackers retrofitting


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The pilot in port of Livorno:

Adaptation of a Reach Stacker vehicle to a different motorization for reducing

environmental impact and energy consumption.

PILOT PHASES:

Design of a Reach Stacker that adopts

alternative environmental compatible

fuelling (i.e. LNG or hydrogen cells)

Integration and realization of a

prototype according to the design

Functional testing of the prototype

Pilot of the prototype and analysis of

performance in a real PCT

The choice of Reach Stackers retrofitting


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Activity 3. Pilot and Demonstration: Main actors involved in the pilot.

Terminal Darsena Toscana Livorno


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Step 1: Choice of retrofitting technology

Activity 3. Pilot and Demonstration: adaptation of a diesel Reach Stacker to a dual fuel engine.

Dual Fuel Diesel/LNG

LNG Hydrogen CNG

Environm. Aspect

Technical Aspect

Econom. Aspect


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Dual-fuel solution has many advantages: • Installation is not invasive and the system is reversible. • Reach Stacker can operate at 100% diesel fuel, so is not “LNG refueling station

dependent”. • It does not reduce the original performances of the reach stacker. • Compared to the CNG solutions it requires a smaller LNG tank volume:

• Reduces the GHG and other pollutants emissions. • Good results under cost-benefits aspect point of view (operating fuel costs

saving). • Safety of LNG compared to CNG and H2. • Possible easy conversion of reach stacker fleet to dual fuel systems. • The payback period will be 7 years and IRR will be 11.89%.

Diesel 1 Liter CNG 5 Liters LNG 1,8 Liters (at -160°C)


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Step 2: Choice of Reach Stackers Brand and Model


KALMAR DRF 450/65S5

CVS F478

KONECRANES SMV TB5

Flexibility in LNG Tank dimentioning and positioning:

Cummins QSM11

Volvo TAD 1250 VE

Choice of Engine


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Choice of LNG tank location and size definition

Step 3: Design and adaptation of the LNG tank for the reach stacker

Necessary to modify the bodywork in order to allow the refuelling

2 Under the chassis in front of the rear wheels

3 Vertical on the right sight of the cockpit

Refuelling difficulties

Activity 3. Pilot and Demonstration: Design and adaptation of the Reach stacker.

1 Horizontal on the right sight of the cockpit.

Sensitive to possible lateral bumps and

collisions

Design of an LNG tank container


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- Design of LNG Tank - Construction of LNG Tank Container

- Construction of LNG Tank

Step 3: Design and adaptation of the LNG tank for the reach stacker


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Step 4: Kalmar’s Cummins engine retro-fitted with d-gid technology

Ecomotive Solutions


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Results of Dyno bench tests at maximum loads


Diesel Consumption

0,0

10,0

20,0

30,0

40,0

50,0

60,0

70,0

80,0

800 1000 1100 1200 1400 1600 1700 1800 1900 2000

Giri [rpm/min]

Co

ns

um

o G

as

oli

o [

lt/h

]

Originale

Dual Fuel

• the dual fuel powered engine does not show any decrease of power compared to diesel, even at maximum load;

• Diesel substitution rate varies from 60% at low rpm to 35% at high rpm (at the maximum load).

• the oil temperature, the exhaust temperature, the intake manifold pressure and LAMDA don’t show significant differences between the dual fuel powered engine and the diesel powered engine;

Activity 3. Pilot and Demonstration: Compared tests covering the whole operating cycle.

Fuel average consumption Diesel Dual Fuel

Average substitution rate of 50% 16 lt/h Diesel 8 lt/h;

LNG 7 kg/h

Economic results Diesel Dual Fuel

Fuel cost savings 21%

average per year from € 18,000 € 19,2* € 15,2*

CO2 reduction Diesel Dual Fuel

Average CO2 emissions reduction 8%

Average per year 15.000 Kg 42,6 Kg/h** 39,3 Kg/h**

*Diesel costs in Italy 1,2 €/lt; LNG costs 0,8 €/lt. ** 2,566 kg CO2/liter of LNG; 2,663 kg CO2/liter of Diesel.

Feedback from the international logistic field about the prototype and further developments.

GREENCRANES, AN ACTION DEVELOPED THANKS TO:

For more information: [email protected]

Consortium:

THANKS FOR YOUR ATTENTION!

mailto:[email protected]

Documents

GREENCRANES Final Info Days - Port of Valencia...FINAL INFORMATION DAY BRUXELLES, 15 MAY 2014 GREENCRANES Final Info Days First European LNG Dual Fuel Reach Stacker Prototype Global