Energy and Data
Management Systems
1
Why we are here
Why battery on RTG crane?
Benefits with energy storage
• Reduced fuel consumption and emissions
• Reduced engine maintenance
• Zero emission operations
Global trends
• Stricter requirements on emissions based on
environmental concerns and global warming
• Zero emission ports
• Battery cost is declining rapidly
2
CxW Energy Storage Solution
Reference overview – Feb 2021
• Hybrid-RTG
Battery & Diesel-engine / Cable reel
After battery finishes charging ~60min (during
charging, RTG is still under uncompromised
operation), battery can support RTG operating
~120min.
57x
145kWh/148kWh/112kWh… …
Within container block, the battery is charged by
conductor rail and can also support hoist up with
reduced speed.
Outside container block, the battery can support
gantry travel ~1.5km
3
7.95MWh
DG
• FE-RTG
Battery & conductor rail
Energy Storage
44x
43kWh/32kWh… …
Energy Storage
1.55MWh
CxW Energy Storage Solution
Hybrid-RTG
• System configuration
Battery-room, provided by CxW, mainly includes:
Engine-room
- Battery system
DG
- DC/DC converter
- Breaker, isolation switch, contactor, relay etc.
E-room
Battery-room
CXW
- PLC, HMI etc.
- Liquid cooling system
Battery
M
Braking resistor Gantry
4
M
M
Trolley Hoist
Auxiliary
Power
Hybrid-RTG
Overview
• Energy flow
Scenario 1
DG
DG
- DG (Diesel Genset off)
- Battery acts as the only power source for RTG operation
- SOC decreases from 65% to 35%
Battery
M
Braking resistor Gantry
Scenario 2
M
Battery
M
Trolley Hoist
M
Auxiliary
Power
Braking resistor Gantry
DG
M
M
Trolley Hoist
Auxiliary
Power
DG
- DG (Diesel Genset starts) once SOC lower than 35%
- DG and battery act together as the power source for RTG
operation
Battery
- SOC increases from 35% to 65%
5
M
Braking resistor Gantry
M
M
Trolley Hoist
Battery
M
Auxiliary
Power
Braking resistor Gantry
M
M
Trolley Hoist
Auxiliary
Power
CxW Energy Storage Solution
Hybrid-RTG
• RTG uncompromised operation
Even when battery is being charged,
RTG operation would never be
disturbed.
Total 16 battery (charging-discharging) cycles within 48h.
Almost 3h per cycle.
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CxW Energy Storage Solution
Hybrid-RTG
• Key features
• RTG is euippend with a full size battery system which drives all crane operations and a small size diesel genset which charges
battery when necessary.
• Regenerative energy during container lowering is fully utilized to charge battery.
• Hybrid solution results in considerable fuel savings compared to conventional RTG.
• No extra yard infrastructure, like motorized cable reals or conductor rails in electrified system using grid power, is necessary.
• RTG maintains full operational flexibility, e.g. Block changes.
• Small diesel genset automatically starts when battery SOC reaches lower limit.
• RTG normal operation would not be interrupted when battery is charged.
• Remote access to the operation parameters/status.
• Fuel savings potential of 60%, compared to conventional RTG
• Reduced emissions and noise.
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CxW Energy Storage Solution
Hybrid-RTG
• Components – battery room
Battery-room, customized design by CxW
- Meet space requirement
- Suitable different installation place
(above/below sill beam)
- Interface (electrical, communication) based
on OEM requirement
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CxW Energy Storage Solution
Hybrid-RTG
• Onsite photos (Panel design)
Door 1,2,3
Door 4,5,6
9
CxW Energy Storage Solution
Hybrid-RTG
• Onsite photos (Walk-in design)
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CxW Energy Storage Solution
Hybrid-RTG
• HMI and IOT
HMI (human machine interface) user panel in the
battery room for maintenance, trouble shooting and
quick access to relative parameters.
IOT (internet of things) can be sued by customer
by PC or phone to remotely monitor battery
system and RTG data.
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CxW Energy Storage Solution
Hybrid-RTG
• Return of Investment (ROI)
Container lifting cost:
140,000
120,000
example 200 moves/day, estimated 60% fuel saving:
120,000
Diesel RTG fuel cost =
2 L/move * 1 USD/L * 200 moves/day * 300 day/year= 120,000 USD/year
100,000
Hybrid RTG fuel cost =
0.8 L/move * 1 USD/L * 200 moves/day * 300 day/year= 48,000 USD/year
80,000
60,000
48,000
Typical investment cost of Hybrid system:
195,000 USD for new RTG
40,000
Rol (Investment cost / Fuel savings)
= 2.7 years for new RTG
20,000
0
Container Lifting Cost
Diesel RTG
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Hybrid RTG
Please note:
- Maintenance cost savings not considered
- Emission cost savings not considered
- The above calculation is indicative only and actual savings and RoI are depending on local diesel
fuel cost and on various operational parameters. Actual analysis needs to be assessed together
with customer.
Integration and dimension
CxW Energy
Solution
How toStorage
integrate battery
into RTG
Integration and dimension
• Battery sizing
RTG power demand is critical to size battery capacity. Such information, no matter onsite measurement value or
power calculation statement, is needed from customer side as design basis.
Analyze user case
The input information includes:
• Hoist continuous power @rated load/speed
• Gantry continuous power @rated load/speed
• Trolley continuous power @rated load/speed
• Auxiliary power @rated load/speed
• Container move number per day
Prepare operational profile
RTG power demand determines battery capacity, which is formed by different numbers of battery modules. Finally, sizing
battery is choosing battery module number.
Max. RTG con. power
Hoist con. Power
+
Trolley con. Power
+
Aux. power
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Power demand level
Battery module number
Battery system capacity
Battery system voltage
~250
5
92.5
340~410
250~300
6
111
408~492
300~350
7
129.5
476~574
350~400
8
148
544~656
Use sizing tool
kWh
Quatation from
BU-ERTG
Battery kWh
CxW Energy Storage Solution
Battery system
• Structure of a battery system
Battery system, customized design by CxW
- Battery cell with UL and CE certificate
- Battery module with air-cooling and liquid-cooling
design
- Battery pack includes modules in series (module
number depends on RTG crane operation profile)
Cell (block)
14
Module
Room
CxW Energy Storage Solution
Battery system
• Battery module for hybrid RTG
15
CxW Energy Storage Solution
Battery Management System (BMS)
• Why is it needed?
• Measure
• Cell voltage
• Cell temperature
• Current
• Manage
• Protect
• Balance
• Thermal control
• Calculate
• State-of-Charge
• State-of-Health
• Maximum charge/discharge limits
• Control/Communicate/Log data
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Battery Introduction
Battery introduction
li-ion battery cell
The lithium-ion battery
Cylindrical
Pouch
Prismatic
Wound or stacked electrode layers
Loosely wound or stacked jelly rolls
Cylindrical wound
– Contained in polymer pouch
– Contained in rigid prismatic container
– Largest global production (18650)
• High energy density
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• Good cooling performance
• Lower energy density (Dead
weight in container)
• More difficult integration, may
deform (swell)
• Normally more difficult to cool due
to larger thickness
• Used mostly in small devices such
as laptops, power tools, e-bikes
etc.
• No controlled release of gases
• Rigid structure makes integration
easier
• Used by Tesla Motors and number
of startup EV makers
• Release of overpressure through
safety valve
• Complex cooling
• Highest energy density
Battery introduction
The lithium-ion battery
Cell category and characteristic
• NMC
Lithium Ion Cell Chemistries
• LFP
NCM
LFP
LTO
Arcronym
NCM
LFP
LTO
Discharge Power
Chemistry performance attributes
Energy
• LTO
Cell Size
, NMC
Charge Power
Cost
Safety
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Cycle Life
Cathode (+ Eletrode) Anode (- Electrode)
NCM
C
LFP
C
NCM, LMO, NCA or LFP
LTO
Nominal Voltage
3.7V
3.2/3.3V
2.3V
Energy - specific energy (mass) & energy density (volume)
Discharge Power - maximum continuous discharge rate
Cost - production volume cell cost. Farthest out along axis = lowest cost
Cycle life - number cycles at the same DOD and temperature to end of life (EOL)
Safety - aggregate of the cell's ability to tolerate destructive overcharge, short circuit,
heating or mechanical abuse
Charge Power - maximum continuous charge rate
Cell size - maximum capacity cell commercially available in high quality serial production
Battery introduction
The lithium-ion battery
• Battery test
- Durapower
- Calendar/cycle aging test
- Thermal stabilization test
- Specific heat capacity test
- Insulation resistance test
- Long lifetime (design lifetime calculation based on
calendar aging and cycle aging: lifetime
expectation > 8 years)
19
Questions?
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