Case Study - Electric Transportation
Electric Cable Reel Rubber-Tired Gantry Cranes:
Costs and Benefits
Executive Summary
This case study explores the economic and environmental issues surrounding the adoption of cable
reel electric rubber-tired gantry (RTG) cranes by seaports. Diesel RTGs can represent a large per-
centage of a port’s total fuel consumption depending on port size and equipment usage. Electric
cable reel RTGs, relatively new to the U.S. market, may reduce port operating costs associated with
RTGs due to lower energy costs and higher energy efficiencies. Existing diesel RTG cranes can be
converted to electric cable reel at a cost of approximately $250,000, allowing ports to take advan-
tage of electric equipment operating benefits. In addition to the economic benefits, electric cable
Table of Contents
reel RTG cranes—both new and converted—save thousands of gallons of diesel fuel and associated
Executive Summary 1
emissions every year.
Introduction 1
Electric Cable Reel
RTG cranes 2
Introduction
Commercial Availability 2
Increasing focus on air quality control by local, state and federal government has caused many U.S.
Infrastructure ports to consider cleaner equipment technologies—including electric—for their equipment needs.
Requirements 4
Port equipment manufacturers have responded by creating a variety of cleaner equipment, and
Equipment Retrofits 4 making more electric equipment available to ports. Included in this equipment is the rubber-tired
Conductix-Wampfler gantry (RTG) crane, which was historically available only with a diesel engine.
E-RTG 4
Gantry cranes are large mobile cranes in widespread use at ports around the world. They are used
Paceco Electric Cable land-side to stack and move containers around a terminal. The gantries on which the cranes are
Reel Carrier 5 mounted move either on rails or rubber tires. RTG cranes typically ride on 16 wheels. At busy
Benefits of Electric container ports, RTG cranes can be run almost around the clock; it is common to find RTG cranes
Cable Reel RTG working 4,000–5,000 hours per year. In the U.S., RTG cranes can represent up to 50% of a port’s
Cranes 5 total fuel consumption depending on port size and equipment usage.1
Economic Benefits 6
At ports or terminals having such heavy usage and reliance on RTG cranes, any improvement in
Operating Costs 6 RTG crane operating efficiencies has a potentially enormous impact on a port’s financial bottom
Maintenance Costs 6 line. The RTG crane, currently at an average purchase price of $1–2 million, has until recently been
Infrastructure Costs 6 used in the U.S. as diesel equipment. The increasing price of diesel fuel, along with pressure on
ports to reduce equipment emissions, has prompted cleaner, more efficient RTG cranes, including:
Cost Summary 7
Environmental Benefits 7 • Electric cable reel systems
Conclusions 8 • Electric hybrid drives
1
Conductix-Wampfler marketing literature: “Drive-In Electric RTGs Make Green Ports a Possibility.” May 2009.
Copyright © 2010 Electric Power Research Institute March 2010
0
• Use of regenerative braking
• Improved internal combustion engine efficiencies
These technologies, particularly the cable reel electric system, have allowed RTG cranes to become
not only cleaner but also more energy and cost efficient.
A diesel crane
idles as much as Electric Cable Reel RTG Cranes
30–40% of the time, Electric cable reel RTG cranes operate using a plug-in electric feed system in place of a diesel en-
consuming diesel gine to power the equipment. The electric feed cable can vary in length with a maximum running
fuel and emitting distance of up to 4,000 feet, depending on need and voltage. The cable is typically stored in a cable
pollutants as it idles. reel located on the RTG, although some vendors use different storage mechanisms. In some cases,
the power cord used for electricity delivery may restrict the crane’s movement. The electric cable
reel RTG crane draws power only when it is needed for moving or lifting, giving this equipment a
major energy efficiency advantage over the diesel RTG crane. A diesel RTG crane idles as much as
30–40% of the time, consuming diesel fuel and emitting pollutants as it idles.2
Electric cable reel RTG cranes typically use a voltage supply of 13,800 volts, but voltage can vary
by port. These cranes may operate for several thousand hours each year, consuming approximately
400,000 kWhs of electricity annually.3
Past concerns about operational flexibility—how far an electric RTG crane can travel and whether
it can negotiate turns as necessary—have been addressed with various cable technology options that
allow for additional crane flexibility and mobility. Technology options include:
• Cable reel carrier system
• Extended cable lengths
• Trenching
• Mounted reel
Commercial Availability
Although some crane manufacturers such as Kalmar and Konecranes have sold electric cable reel
RTG cranes in Europe for several years, the U.S. market has been less robust. Interest in them in
North America is due in part to the current regulatory environment in the U.S. encouraging cleaner
technologies. Kalmar’s first electric cable reel RTG, called the “zero emission” RTG, was delivered
to the Port of Oslo, Norway in 2002.4 The system maximizes energy efficiency by allowing the
crane to reuse accumulated energy. Kalmar estimates its zero emission RTG crane energy costs to
be roughly 20% of hybrid diesel-electric.5 RTG crane energy costs—themselves much lower than
diesel energy costs—depend on the comparative costs of electricity and diesel fuel.
2
California Air Resources Board. presentation: Cargo Handling Equipment Idling Emissions, September 16, 2009.
http://www.arb.ca.gov/ports/cargo/idle/presentations/091609present.pdf.
3
Based on modeling using EPA’s NONROAD model using a load factor of 0.20. This load factor is, we believe, in line with this crane’s usage
and profile.
4
Kalmar Corporate Marketing Material. Kalmar RTG: Zero Emission.
5
Ibid.
2 0 Electric Cable Reel Rubber-Tired Gantry Cranes: Costs and Benefits
Photo 1. Konecranes cRTG
Konecranes markets its electric cable reel RTG crane, called the “cRTG” (photo 1).6 The cRTG is
also electrically fed, utilizes a cable reel, a feeding cable, and a transformer station to provide power.
The cRTG running length can be a maximum of 4,000 feet, depending on feed point location. An
auxiliary diesel generator unit is fitted to power the crane as it moves from container stack to stack,
where the crane is then reconnected to another feed point using a plug and receptacle. cRTGs offset
their power use through reuse of accumulated energy, with the energy generated during container
braking actions fed back to the grid. As a result, the terminal may draw less power from the power
grid.7
Because the electric cable reel RTG crane is so new to the U.S. market, cost information is prelimi-
nary and is largely dependent on the configurations and demands of specific ports. Cost per unit for
electric cable reel RTG cranes may be marginally higher when compared to diesel units, with costs
expected to be equalized after market demand allows electric equipment to be produced on a large
scale. As stated above, current RTG crane pricing for a typical unit is $1–2 million.
6
KoneCranes Marketing Material. Low Emission Concept: When Less is More.
7
Cranes Today Magazine. Going for Green. September 15, 2009. http://www.cranestodaymagazine.com/story.asp?storycode=2054118.
Electric Cable Reel Rubber-Tired Gantry
0 Cranes: Costs and Benefits 3
Infrastructure Requirements
Infrastructure upgrades may be necessary in order to effectively service new electric equipment at
a port terminal. Every port has its own electric needs. Therefore, a cost estimate for any electric
infrastructure upgrades necessary to service electric equipment, new or converted, will depend on
current infrastructure and the local area electric utility. Newer ports or terminals that have ample
electrical capacity and infrastructure in place may have minimal infrastructure upgrade needs in
order to serve new electric cable reel RTGs added to their fleets, while other ports may need to make
an initial investment in order for these RTGs to be effectively serviced. Many ports, like the Ports of
Houston and Savannah, for example, have already made electrical infrastructure upgrades for their
fleet of electric ship to shore cranes—an increasingly common piece of equipment at ports—and
may, as a result, have only minor additional upgrades to be made for electric cable reel RTGs added
to their fleets.
These electric cable reel models typically use electric power from the shore with an electrical service
requirement ranging from 4,160 to 13,800 volts depending on use and specifications. Electrical
infrastructure that may need to be added can include:
• High voltage source and switchgear infrastructure
• Electrical power from substation to crane switchgear infrastructure
• Cabling from switchgear infrastructure to the crane vaults/pits
Because of the Equipment Retrofits
relatively long useful Several ports have recognized the potential benefits of electric equipment, and are investigating
life of the typical equipment conversions. These ports include Los Angeles and Long Beach, which have provided
RTG, even an older funding for their tenants to retrofit existing diesel RTG cranes with electric cable reel systems.
diesel RTG converted Other ports are also starting to consider electric cable reel RTG cranes. A recent announcement
to electric cable reel indicated that Hong Kong International Terminals would convert 81 diesel cranes to electric cable
can offer economic reel by this year.8
benefi ts.
Converting an RTG crane to electric cable reel involves replacing the diesel engine with a trans-
former, cable and electric components. This retrofit can cost between $200,000 and $300,000 and
requires electrical infrastructure to support the cranes. Whether or not the conversion offers an
economic benefit depends on such factors as existing electrical infrastructure, the remaining useful
life of the crane and how much the RTG is used. Because of the relatively long useful life of the
typical RTG—as much as 25 years—even an older diesel RTG converted to electric cable reel can
offer economic benefits over the remaining life of the equipment.
Electric cable reel RTG conversion vendors such as Konecranes, Conductix-Wampfler and Paceco
can utilize one of several technologies for power system conversions on the cranes, including:
Conductix-Wampfler E-RTG
The Conductix-Wampfler E-RTGTM uses one of two electric power systems on its conversions depending
on the needs of the port: the motorized cable reel or the conductor rail.
The motorized cable reel system involves the mounting of a cable reel onto the crane. Custom-
ers can choose one of two technologies with this system: a motorized cable reel with permanent
8
China Real News, June 3, 2008, Hong Kong International Terminals Plans to Cut Carbon Dioxide Emissions by 7,000 tons.
4 0 Electric Cable Reel Rubber-Tired Gantry Cranes: Costs and Benefits
magnetic coupler or a frequency controlled motorized cable reel. Conductix-Wampfler estimates
that the payback period in most cases for their RTG crane conversion is 12–18 months.9
An alternative to the cable reel is Conductix-Wampfler’s rail system (Photo 2). With this system, it
is not necessary to manually plug the RTG into the current collector trolley of the conductor bar
system. Instead, the current collector trolley is automatically steered to the guide rails of the steel
structure when the RTG enters the aisle, and the current collector is safely guided into the conduc-
tor bars. This “drive-in” solution saves time and energy, increasing the efficiency of a terminal while
reducing its environmental burden.
Paceco Electric Cable Reel Carrier
The Paceco electric cable reel carrier (CRC) system uses a cart that travels alongside the crane and
holds the power cable. This electrification method is simple in that it eliminates the need for com-
plex guidance mechanisms or ground modifications. One of the challenges of crane electrification
is that RTG cranes can stray significantly from straight line paths, which complicates the matter of
drawing and laying down power cables in their fi xed enclosures. The CRC addresses this challenge
with a separate rolling cart, which follows a cable guide channel. The CRC is mechanically linked
to the RTG crane so that it can remain alongside the crane to supply power.10
Benefits of Electric Cable Reel RTG Cranes
There are many potential benefits to using electric cable reel in place of diesel RTG cranes, including
• greater energy efficiency
• reduced operating and maintenance costs
• longer equipment life
• reduced emissions
• no need for refueling
Photo 2. Conductix-Wampfler Conductor Rail System
9
E-RTGTM RTG Electrification, Conductix-Wampfler marketing literature.
10
“Paceco marketing material. Electrified RTG Cable Reel Carrier. http://www.pacecocorp.com/prertgcrc.shtml.
Electric Cable Reel Rubber-Tired Gantry
0 Cranes: Costs and Benefits 5
Economic Benefits
The economic benefits of electric cable reel RTG cranes are a result of increased energy efficiency,
lower energy costs, and less maintenance and downtime compared to a diesel RTG.
Operating Costs
Electricity costs are lower and more stable than diesel fuel in most parts of the U.S. Using an aver-
age industrial rate of $0.08 per kWh11 compared to off-road diesel fuel at an average of $2.30 per
gallon, running RTG cranes on electricity is more economical.12 For example, a 650 horsepower
diesel RTG crane operating 4,000 hours per year uses about $72,000 worth of diesel fuel annu-
ally (priced at $2.30/gal). By comparison, an electric crane utilized the same number of hours uses
about $32,000 worth of electricity annually, assuming 407,000 kWh at $0.08 per kWh (see Table 1)13.
Some estimates, such as Conductix-Wampfler’s analysis of the benefits associated with their E-RTG
conversion, show an even greater benefit for electric cable reel RTG crane operations.14 Note that this
example does not factor in electric cable reel RTG crane maintenance or infrastructure costs, both
of which are discussed below.
Maintenance Costs
Maintenance costs for electric equipment are typically lower than for diesel equipment. Frequent
oil changes, engine tuning, diesel-related failures, regular diesel engine replacements, and longer
equipment down time are all common with diesel equipment. In an industry that requires its equip-
ment to be up and running in order for operations to run smoothly, this equipment down time can
affect a port’s bottom line. At the Port of Savannah, for example, 25% of the port’s equipment down
time is directly attributed to diesel-related issues.15
Infrastructure Costs
Electrical upgrades and additional infrastructure may be required to run electric cable reel cranes
from dock-side power. Again, every port has its own needs, so it is impossible to estimate the
Table 1. Cost Comparison Between an Electric and Diesel RTG Crane
Electric Cable Reel
Diesel RTG Crane ($)
RTG Crane ($)
Equipment Cost 1.5 M 1.65 M
Annual Operating Cost 72,164 32,573
20-Year Operating Cost 1.44 M 651,460
Assumes 20-year life, 650-horsepower diesel engine, 4,000 hours per year operation, load
factor of 21%; a diesel equipment price of $1.5 million, an electric RTG crane purchase price
of 1.10% that of diesel, diesel fuel cost of $2.30 per gallon, electricity cost of $0.08 per kWh.
11
http://www.eia.doe.gov/cneaf/electricity/epm/table5_6_a.html.
12
http://tonto.eia.doe.gov/oog/info/wohdp/diesel.asp. Average on road diesel fuel price is $2.80/gal; subtracting $0.50 tax equals
off-road price.
13
Modeling assumptions include: a load factor of 0.20, a 650 horsepower pre-1990 engine, equipment usage of 4,000 hrs per year, and CO2
was based on the carbon content of the fuel using the following equation: CO2 EF = (BSFC * 453.6 – HC) * 0.87 * (44/12) where BSFC is
from the NONROAD model and is expressed in terms of pounds per HP-hour.
14
E-RTGTM RTG Electrification, Conductix-Wampfler marketing literature.
15
Per communication with Rich Cox, 2009.
6 0 Electric Cable Reel Rubber-Tired Gantry Cranes: Costs and Benefits
infrastructure investment required to support electric cable reel RTG cranes. Newer ports or ter-
minals that have ample electrical capacity in place may not require additional infrastructure, while
older facilities may need to make an initial investment. Various stakeholders—including port ten-
ants and the local electric utility—in addition to the port itself may contribute to defraying the cost
of electrical upgrades.
Cost Summary
The energy efficiency and cost savings of an electric cable reel RTG crane compared to its diesel
counterpart can result in a substantial cost advantage, the specifics of which depend on the prices
of electricity and diesel fuel. Over a 20-year equipment life, this savings can add up to hundreds of
thousands of dollars (see Table 1).
Environmental Benefits
Emissions from port operations are increasingly being scrutinized because of environmental and
regulatory pressures. As a result, diesel emission reduction programs have been established at most
larger ports. These programs often include efforts to reduce diesel equipment emissions through the
use of alternative fuels and electricity. Equipment that runs on electricity produces no operating, or
tailpipe, emissions. The emissions associated with electric equipment are those emitted due to the
generation of electricity. These emissions compare very favorably to those from diesel equipment.
In the case of an RTG crane, the net reduction can amount to several tons per year of many major
pollutants.
Table 2 shows an average16 pre-1990 RTG diesel crane emissions and fuel usage profile. As shown, a
typical diesel RTG crane emits annually approximately six tons of nitrogen oxides (NOx) and 350
tons of carbon dioxide (CO2)—about the amount of CO2 emitted by 63 passenger cars in a year.17
Although there are no tailpipe emissions from an electric cable reel RTG crane, there are emissions
associated with the generation of electricity used to power the crane. Depending on the source of
electricity, these emissions can vary widely. A national average for carbon dioxide emissions from
power plants of 1.35 lb/kWh is assumed for this analysis.19
Using this national average for CO2 generation emissions, an RTG crane that is operated 4,000
hours per year will use an estimated 407,000 kWh per year, the generation of which is associated
Table 2. Annual Emissions for a Typical Diesel RTG Crane18
Emissions (T/yr)
NOX HC CO PM CO2
5.8 0.4 1.6 0.2 354
NOx: nitrogen oxide; HC: hydrocarbon; CO: carbon monoxide; PM: particulate matter;
CO2: carbon dioxide.
16
Based on 650 horsepower pre-1990 engine, and equipment usage of 4,000 hrs per year.
17
Assuming vehicle emits 25 lbs per year of NOx and 5–6 tons per year CO2. Environmental Defense Fund, Tailpipe Tally.
18
Modeling is based on RTG crane load factor of 0.21 and EPA’s NONROAD model; assumptions include: a 650 horsepower pre-1990
engine, equipment usage of 4,000 hrs per year, and CO2 was based on the carbon content of the fuel using the following equation: CO2 EF
= (BSFC * 453.6 - HC) * 0.87 * (44/12) Where BSFC is from the NONROAD model and is expressed in terms of pounds per HP-hour.
19
http://www.eia.doe.gov/pub/oiaf/1605/cdrom/pdf/e-supdoc.pdf.
Electric Cable Reel Rubber-Tired Gantry
0 Cranes: Costs and Benefits 7
Table 3. Annual CO2 Emissions Associated with a Diesel and Electric RTG Crane
Annual Energy Use
Equipment Type CO2 Emissions
at 4,000 hr/yr
Diesel Crane 31,376 gal 354 typ (tailpipe)
Electric Crane 407,000 kWh 275 typ (power plant)
with 275 tons of CO2 emissions. This estimate represents a decrease of approximately 22% compared
to a diesel crane.
Conclusions
Due to lower energy costs and energy efficiencies, the electric cable reel RTG crane can offer en-
ergy savings compared to its diesel counterpart. Existing diesel RTG cranes can be converted to
electric cable reel at a cost of approximately $250,000, allowing ports to take advantage of several
electric equipment operating benefits. In addition to the economic benefits, electric cable reel RTG
cranes—both new and converted—save thousands of gallons of diesel fuel and associated emissions
every year.
Contact Information
Andra Rogers, Senior Project Manager, Electric Transportation
Electric Power Research Institute
3420 Hillview Ave., Palo Alto, CA 94304
Phone: 650.855.2101, Fax: 650.855.2737, Email: [email protected]
Research Contractor
Starcrest Consulting, LLC
P.O. Box 434, Poulsbo, WA 98370
Principal Investigator
K. Bishop
The Electric Power Research Institute Inc., (EPRI, www.epri.com) conducts research and development
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