Konecranes introduces a new type of fuel-saving RTG crane featuring a variable-speed diesel alternator system. This innovative solution diminishes fuel consumption significantly by eliminating high-speed idling, and it reduces noise and emissions
Fuel consumption is the critical issue in any yard where hundreds of containers are handled each day. Konecranes has developed the technology to cut down fuel costs of modern RTG. The objective was to come up with a solution that would allow handling containers with a little fossil fuel as possible, thus reducing with the noise and emissions. Simultaneously the productivity of RTG should not be compromised. The productivity of fuel-saving RTGs should be equal to that of normal RTGs. Initially, the idea was to use as many reasonably priced, previously used components as possible but combine them in a new way.
Challenging traditional thinkingKonecranes analysed that programmable logic controllers can be used to calculate the generator power needed and to regulate the engines running speed. Konecranes invested lot of efforts to develop a unique voltage regulator with its suppliers, which was different from normal ones in that output voltage of the alternator was most linear with the rotation speed of the alternator’s axle. When the rotation speed changes, the frequency and voltage changes correspondingly. Instead of a constant voltage, it is variable. Having seen the principle of this voltage regulator in action, Konecranes realised that once they had developed the diesel motor control algorithm, the rest of the project would not be a problem. Volvo penta, a regular supplier of Konecranes helped to understand the control of a modern diesel engine.
Duty Cycle is the KeyWe believe that RTG duty cycle is the key to fuel savings. Konecranes has studied the real operation of port RTGs and has established that most of the usage time consists of 0 per cent to 25 per cent load, with 75 to 100 per cent of full capacity representing only the marginal part of power spectrum. This shows that high speed idling produces enormous fuel losses, and it demonstrates the need to produce only the amount of energy that is really needed at any given time.
Konecranes fuel-saving system operates on the principle of calculating the power needed by the PLC and the diesel engine speed is adjusted to be equivalent to the power required. The PLC contains all the intelligence inherent in the system and it has several cutting-edge features. The diesel engine is driven with optimal efficiency at all operating points, which eliminates high-speed idling completely. The DC-bus voltage is controlled by the active supply unit, which functions independently from the speed of the diesel alternator. Full scale productivity is thus also available with lower diesel alternator speeds. The less speed, the lower the losses, with less fuel consumed and diminished fuel consumption results in lower noise and fume emissions.
Rapid Return on InvestmentKonecranes has always been on forefront of technological development and the new integrated intelligent fuel-saving system is an important additional functionality that brings added value to our RTG customers. The investment in fuel-saving RTG pays for itself very quickly. The initial investment costs might be higher because of its active electronic components involved, but the product pays itself within a couple of years, owing to the great savings in fuel costs.

Contact:Konecranes India Pvt. Ltd.19, Level II, Mutha Towers, Don Bosco Road, YerwadaPune-411006, INDIATel.: +91-20-4141 3484