1. Ultracap systems

2. Energy recuperation
Potential energy
Kinetic energy

3. Local energy-storage for machines
Energy Entry
Recovered energy
Energy loss
Energy loss
Recovered energy
maindrive
Energy loss
process
Process

4. Electrochemical Energy Storage

5. Lifetime vs. Efficiency
Source : www.electricitystorage.org

6. Conventional crane
Heat
=
Brake Losses
Tank
Main Main hoist
Generator Inverter Inverter
diesel motor
Hoistbek
Inverter
motor
Boardnet
load Toppen
Inverter
motor
Swing
Inverter
motors

7. Workcycle conventional crane
1000
900
800
700
600
500
grijper start open
400 Grijper down
300
P Sluit [kW]
200
100 P Hijs [kW]
0
DC BUS Spanning
-100 [V]
-200 P Top [kW]
-300 P Zwenk [kW]
-400
grijper empty Ptot [kW]
-500 grijper full & up
-600
0 10 20 30 40 50 60 time [seconds]

8. Crane cycle
Savingspotential
• Length = 55 sec
• Max power = 970 kW
• Max load = 33 Ton
• Consumed electrical energy = 10687 kJ (100%)
• Dissipated electrical energy = 4746 kJ (44%)
• Average power = 106 kW
• Required energy buffer = 1.6 kWh
• Required condensator = 20.5 F (425V..850V)
• Required converter = 860 kW (1500 A)

9. Conventional crane
Potential improvements
• Reduction of Fuel Consumption
– Main Diesel, brake chopper
• Reduction of emissions
– Main Diesel NOx, PM (soot)
• Increased Productivity
– Peaks on DC bus
• Reduction of Noise
– Main Diesel

10. Hybrid Crane
Energy-storage System Heat
=
Buffer Convertor Brake loss
Tank
Main Main hoist
Generator Inverter Inverter
diesel motor
Hoistbek
Inverter
motor
Boardnet
load Toppen
Inverter
motor
Swing
Inverter
motors

11. Hybrid Crane
Features & Functies – In General
• Installation buffer
– Expansion of capacitance of the DC-bus from mF
to Farad
– Increased voltage stability
– increased energy-capacity
• Additional convertor
– Energy-storage: +130%
– Cost :+40%
– Extra flexibility : choice of priority
(costfunction)

12. Crane cycle
Options with Ucap + converter+ costfunction
• Savings of primary energy by recuperation
– 5% without converter
– 10%+ with converter
• Smaller generator (for new machines)
• Less emissions (PM, NOx)
– With converter till -80% for PM
• Simple settings : one parameter

13. Optimization for energy/fuel:
C=10,2F – V=350..700V
• -31% energy
• -16% fuel
• Soot emissions remain (shorter time but bigger gradient)

14. Optimazation for energy/fuel/soot:
C=10,2F – V=350..700V
• -27% energy
• -13% fuel
• NO soot emissions

15. Optimasation for energy/fuel/soot:
C=20,4F – V=350..700V
• -29% energy
• -15% fuel
• NO soot emissions

16. Hybrid Crane
Our Approach
• Modular approach provides simplicity
– Integration of components on existing DC-bus
– Clear partitioning of functionality
– Simple approach for service and warranty
– NO interventions on conventional function
• “proven” technology (Ucaps, IGBTs, inductoren)
– Available - affordable - validated parts
• Innovative technology (strategy in converter)
– Economically attractive
– No interference with normal operation

17. Hybrid Crane
Our Approach
• Flexible control strategy
– Cost function : sum of costs for
• Delivered power (motor consumption)
• To be stored (to deliver later) power(efficiency UC)
• soot
• other: penalties for emissions/grid peaks
– ONE parameter (cost UC) determines the full control
strategy :
• minimal consumption
• minimal emissions
• peak shaving
– Easy to adapt to machine or workcycle

18. Economical - ecological
Fuel- environment
• Conventional Crane
– Utilization : 3000 hours/year
– Consumtion: 55l/hour
– Emission of NOx, PM10 ?
• Costs of Fuel
– Average cost : 0,65€/l
– Full year : 3000*55*0,65 = ±100k€
• In case of hybrid
– Reduction of fuel by 13%
– Less fuel cost per year : 13k€
– 50 ton less CO2 / year
– Less PM10, NOx – (reduction of 50..90%)

19. Compact DC/DC converter bidirectional
0..740V
250Arms
360 Apeak

20. Ultracap system UCS 1000/14
0,5 kWh
10,7 F
0..740 V
250 Arms
900 Apeak