» IMPROVED EFFICIENCY» IMPROVED PRODUCTIVITY» POWER QUALITY» LOW-CARBON ENVIRONMENT
OUR SOLUTION DELIVERS 2 IMPROVED EFFICIENCY Up to 80% reduced fuel consumption IMPROVED PRODUCTIVITY No need to power limit during hoisting Longer periods between refueling Virtually eliminates Regen cycles on Tier 4 POWER QUALITY Responsive utility grade power Reduced blackouts LOW-CARBON ENVIRONMENT Up to 80% less CO 2 emitted
OUR PURPOSE 3 BluVert is an energy management system for that saves fuel, improves performance, reduces emissions and delivers utility grade power quality. A BluVert RTG solution consists of: Control software Power electronics Energy storage Variable speed generator
HOW IT WORKS 4 Conventional Genset(s) Variable Speed Genset Fuel Cell Energy Storage or or + Core Energy Management & Power Electronics Clean, Efficient & Reliable Power (AC and/or DC)
TYPICAL RTG POWER 5 300-500kW Generator GFS AC Bus Braking Energy is wasted DC Bus House Loads Resistor Hoist Trolley Travel Travel Travel Travel
BLUVERT V.S. GEN - RTG POWER 6 75-100kW Generator Variable Speed Generator VS Gen Core Energy Management E.S. LCL AC Bus Y DC Bus Braking Energy is recovered House Loads Resistor Hoist Trolley Travel Travel Travel Travel
RTG FACTS 7 Seaport terminals worldwide are facing new carbon and efficiency legislations and must change way they operate RTGs. Power conversion technology has caught up to the science behind reliable solid state power and offers reliable stored energy and energy capture. Loads are very cyclic (high lift loads followed by idling) Cycle times vary from 10 to 25 lifts per hour 20 lift/hr x 16 hrs x 300 days = 96,000 cycles per year Traditional fixed speed gensets do not optimize efficiency Large Generators are needed for peak loads (lifting) so they mostly operate at very low load Traditional RTGs do not capture regenerative energy
RTG APPLICATION 8 Gantry Cranes have highly variable loads, which causes the generators to run at <20% average load. This inefficient operation of the gensets results in high fuel consumption and emissions. It also means that new Tier 4 Engines will not operate within their required load range As the DPF clogs, up, power output drops and eventually will turn off requiring a Regen cycle During Regen, the engine cannot be used to power a load (e.g. Generator). Regen can take upwards of 1.5 hours
HOW IT WORKS 9 Variable Frequency Permanent Magnet Generator Requires no external power source to initiate a magnetic field. Demonstrates higher efficiency at partial loads resulting in a proven higher efficiency curve. Starts producing power at lower speeds, adds more power sooner. Simple, rugged PM Generator can be used as Engine Starter for fast transition to Generator Power Thousands are operating worldwide
HOW IT WORKS 10 Variable Frequency Generator Engines Engines operated at lower speeds means lowers fuel consumed per kw Efficiency advantage increases at partial loads Lower speeds means lower maintenance and operating costs than constant speed synchronous generator engines A proven concept in telecom, ship, locomotive, RTG & crane applications
Power V.S. ENGINE - FUEL MAP OPTIMIZATION 11 1000 kw VARIABLE SPEED GENSET (fuel consumption is optimized at every load point) CONVENTIONAL FIXED SPEED GENSET (operates at 1800 RPM regardless of loading) 0 0 Engine Speed 1800 RPM BSFC (Brake Specific Fuel Consumption) CONTOUR LINES
BSFCe (g/kw*h) FUEL SAVINGS 12 The BluVert Variable Speed Genset and Energy Management System optimizes the efficiency and delivers >65% savings. 800 Load vs BSFC 700 600 500 RMS Loading is 35kW with Regen Recovery, 65 kw without Regen Recovery 400 300 Effective BSFC - FS Generator (QSX15) (includes Generator Losses) 200 100 Effective BSFC (QSB4.5) (includes all losses in System) 0 0 50 100 150 200 250 300 350 400 Load (kw) FS Gen BSFCe BluVert VS Gen BSFC
HOW IT WORKS 13 Ultra Cube Seamless solid state energy source designed to absorb any transient load challenge Stored Energy with high life time cycling ability and very low maintenance Clean fast efficient energy charge/discharge with advanced DC-DC + power conversion Power ride-through ensures quality and reliability; mitigates blackout risk
REGENERATIVE ENERGY RECOVERY 14 Ultra Cube BluVert monitors hoist position allowing it to: Capture all of the braking energy produced when lowering Provide instant Power to the load when hoisting Ultra capacitors or batteries are tied to the RTG s DC bus via a DC-DC + Converter Savings of up to 35 % are realized by energy recovery (in addition to savings from more efficient fuel consumption)
Load (%) Load (%) Conventional QSX15 (467kWe) Genset Load Profile 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 200 400 600 800 1000 1200 1400 Time - Seconds BluVert QSB4.5 VS + PM Generator (92 kwe) Genset Load Profile 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% Ultra Cap profile, Batteries will provide a more continuous load profile 0 200 400 600 800 1,000 1,200 1,400 Time - Seconds
Load (kw) 400 Gantry - Load (kw) (House Load Excluded) 8,000 300 7,000 200 6,000 100 5,000 0 4,000 0 200 400 600 800 1000 1200 1400-100 3,000-200 2,000-300 -400 Design Emulation Tools are used to optimally size the energy storage. Storage is designed based on capacity at end of life (i.e. after approx. 10 years) Time -Seconds Load (kw) Cap Bank Power Gen (kw) Cap Bank (kj) (Secondary Axis) 1,000 0
GENERATOR SET COMPARISON 17 STANDARD GENERATOR Operating Speed Fixed RPM Variable RPM Gen Size Optimum Efficiency Fuel Efficiency Oversized for large Transients Right sized based on RMS Load 70-100% Load 30-100% Load Standard > 65% Savings (including Energy Recovery) Energy Recovery N/A > 30% Savings AC Power Quality (100% Step load) DC Power Quality (100% Step load)» Several second recovery» Up to 25% volt/freq dip» Several second recovery» Up to 25% voltage dip» < 100 ms recovery» < 0.1 Hz, < 3% Volt dip» <100 ms recovery» < 15% voltage dip Carbon Emissions Standard > 65% Less * Based on a typical 1MW standard diesel genset, $1.00/liter diesel fuel, 10 year life
STORED ENERGY COMPARISON 18 Battery Ultra Capacitor Application Type HIGH ENERGY CAPACITY HIGH POWER RATING Expected Life 20,000+ cycles 1,000,000+ cycles Environmental 20 C temp control, ventilation, alarms required -40 to +40C Safety Battery OEM s typically incorporate detection and safeties to mitigate thermal runaway to one cell Easy to fully discharge during transportation Power Density Low needs more space High needs less space Power Capability Instantaneous Instantaneous Charge/Discharge Efficiency 95% at high C rates higher at low C rates Up to 97% Maintenance Near Zero Near Zero Comments Note a properly designed Battery system will see significantly less deep charge / discharge cycles than a Ultra Cap based E.S. System
COMPETITIVE ADVANTAGE 19 MINIMAL ENERGY STORAGE» Improved power quality» Capture regenerative lowering energy BEST RTG EFFICIENCY» Saves operating costs 50-60%» Lowest lifecycle cost COMPELLING PAYBACK» Payback depends on comparison to Retrofit cost and actual usage rate of RTG we are happy to provide a payback analysis for your specific application CONVENIENT TO ADOPT» Integrates with any power system BEST LOW-CARBON IMPACT» Carbon emissions reduced 65 80%» Uses current EPA certified engines
WE HAVE YOUR BACK 20 We provide the technical support needed to understand and keep you running.
Contact Us Steven Smit s.smit@prepglobal.com +1 604.882.7093