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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
Page 2
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
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 3
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
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 4
Activity 3. Pilot and Demonstration: Main actors involved in the pilot.
Terminal Darsena Toscana Livorno
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 5
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
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 6
Activity 3. Pilot and Demonstration: adaptation of a diesel Reach Stacker to a dual fuel engine.
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)
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 7
Step 2: Choice of Reach Stackers Brand and Model
Activity 3. Pilot and Demonstration: adaptation of a diesel Reach Stacker to a dual fuel engine.
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
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 8
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
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 9
Activity 3. Pilot and Demonstration: Design and adaptation of the Reach stacker.
- 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
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 10
Activity 3. Pilot and Demonstration: Design and adaptation of the Reach stacker.
Step 4: Kalmar’s Cummins engine retro-fitted with d-gid technology
Ecomotive Solutions
Green Technologies and Eco-efficient Alternatives for Cranes and Operations at Port Container Terminals
Page 11
Results of Dyno bench tests at maximum loads
Activity 3. Pilot and Demonstration: Design and adaptation of the Reach stacker.
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!