HYBRID AND FULLY ELECTRIC POWERING TECHNOLOGYFOR CONTAINER HANDLING LIFTRUCKS:
A LOOK INTO THE SHORTCOMING FUTURE
Davide BertozziDirector – Trade and Development
CVS FERRARI S.p.A.
CONTAINER HANDLING
LIFTRUCKS
(Container Handling)
REACHSTACKERS
MASTED(Container Handling)
LIFTRUCKS
2000 2010 20202015
MARKET LAUNCH OF ALTERNATIVE POWERED (FREELY) MOBILE CONTAINER HANDLERS
SC LFT
HybridStraddle Carriers
HybridLiftrucks
so far noFULL ELECTRIC
Straddle Carrieron the market
SupercapacitorsApplications
on RTGs
Fully ELECTRICRTGs have shore
energy cable feed(not freely mobile)
2005
CONTAINER HANDLING
LIFTRUCKS
(Container Handling)
REACHSTACKERS
MASTED(Container Handling)
LIFTRUCKS
ENERGY EFFICIENCY ATTITUDE
Roller
MASTEDLIFTRUCKS
REACHSTACKERS
very limitedfriction
High Efficiency
extensivefriction
Lower Efficiency
ENERGY RECOVERY ATTITUDEMASTEDLIFTRUCKS
REACHSTACKERS
The Energy Balance is much more favourable for the electric winched mast over the hydraulic cylinders boom
Energy spending
EfiicientEnergy Recovery
OpportunityEfiicient
Energy RecoveryOpportunity
Energy spending
Energy spending
Energy spending
LIFTING MECHANISM
The mast concept allows the effectiveelimination of power hydraulics
and their replacement with electric winches
MASTEDLIFTRUCKS
REACHSTACKERS
The boom concept does not allow the effectiveelimination of power hydraulics
ENERGY EFFICIENCY AND RECOVERY ATTITUDE OF LIFTING MECHANISM
REACHSTACKERS
MASTEDLIFTRUCKS
ElectricPowerSource
_
Storage
ElectricMotor
HydraulicPump
HydraulicLift
Cylinder
ElectricPowerSource
_
Storage
ElectricWinch
The Energy Balance is much more favourable for the electric winched mast over the hydraulic cylinders boom
S
S
P
P
Fact:IT IS VERY LIKELY THAT THE «ELECTRIFICATION» OF THE CONTAINER HANDLING LIFTRUCKS
WILL REVIVE THE POPULARITY OF MASTED LIFTRUCKS
Question:IS THE «ELECTRIFICATION» OF THE CONTAINER HANDLING LIFTRUCKS
IS REALLY GOING TO HAPPEN?
!
?
THE CONDITIONS FOR THE CONTAINER HANDLING LIFTRUCKS «ELECTRIFICATION» TO HAPPENARE:
1) THE PRODUCTIVITY OF THE «ELECTRIFIED» TRUCKS HAS TO BE THE SAME
OR BETTER THAN THE PRODUCTIVITY OF THE CONVENTIONAL POWER TRUCKS
2) THE TOTAL COST OF OWNERSHIP OF THE «ELECTRIFIED» TRUCKS HAS TO BE
APPRECIABLY BETTER THAN THE ONE OF THE CONVENTIONAL TRUCKS
Based on CVS FERRARI equipment data, «electrified» Masted Liftrucks have:
✓ Same Drive Speed of Conventional✓ Better Acceleration✓ Better Maneuverability✓ Better Drive and Lift motion control✓ Much Better Lift and Lowering Speed
PRODUCTIVITY
OK
TOTAL COST OF OWNERSHIP
In essence is made of:
➢Purchase Cost➢ Fuel➢Tires➢Consumables➢Extraordinary Maintenance Costs (Parts and Labour)
CVS FERRARI MANUFACTURES AND HAS FULL TOTAL COST OF OWNERSHIP DATA FOR BOTH:
CONVENTIONAL POWER ECH MASTED LIFTRUCKS HYBRID POWER ECH MASTED LIFTRUCKS
TOTAL COST OF OWNERSHIP
based on the data of CVS FERRARI, the HYBRID ECH, as compared to CONVENTIONAL POWERmachines has:
➢ about 20% higher Purchase Cost➢ about 40% less Fuel Consumption➢ about 35% less Tires Expenditure➢ about 50% less investment in Consumables➢ about 70% less Extraordinary Maintenance Costs
Purchase CostCONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK
100 100
200 200
300 300
400 400
500 500
100 120
- CVS FERRARIProduct Price
- CVS FERRARIProduct Price
(expressed in Relative Terms)
The Purchase price for the buyerof the CVS FERRARI
Conventional Power Truckis conventionally assumed
as being «100»All other values in this
oresentation are expressedIn relation to this one
The price of the equivalentCVS FERRARI Hybridd Power ECHis 20% higher than the price of the
conventional Power Truck
Fuel Consumption
100 100
200 200
300 300
400 400
500 500
192112
- Average cycle- Average (Europe) Fuel cost- 40,000 w/h life
- Average cycle- Average (Europe) Fuel cost- 40,000 w/h life
CONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK(expressed in Relative Terms)
Tires Expenditure
100 100
200 200
300 300
400 400
500 500
50 32
- Average cycle on good ground- No tires damages considered- 40,000 w/h life
- Average cycle on good ground- No tire damages considered- 40,000 w/h life
CONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK(expressed in Relative Terms)
Consumables
100 100
200 200
300 300
400 400
500 500
56 23
- Average Fluids Cost- Average (Europe) Labour Cost- 40,000 w/h life
- Average Fluids Cost- Average (Europe) Labour Cost- 40,000 w/h life
CONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK(expressed in Relative Terms)
Spare Parts
100 100
200 200
300 300
400 400
500 500
14560 - 40,000 w/h life- 40,000 w/h life
CONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK(expressed in Relative Terms)
Labour
100 100
200 200
300 300
400 400
500 500
40 16
- Average (Europe) Labour Cost- 40,000 w/h life
- Average (Europe) Labour Cost- 40,000 w/h life
CONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK
100 100
200 200
300 300
400 400
500 500
100 120
192
5056
145
40
112
3223
16
60
363
S
- 40%=over 2 timesthe purchase costof the truck
TOTAL COST OF OWNERSHIP
CONVENTIONALPOWER TRUCK
HYBRIDPOWER TRUCK
(expressed in Relative Terms)
100
4800 40000
- 40%
CONV
HYBR
TCO
WORKHOURS
Pay-Back Time isbetween 1 or 2 years based on work intensity
TOTAL COST OF OWNERSHIP(Pay-Back Time of Hybrid Price Premium)
(expressed in Relative Terms)
Fact:«ELECTRIFICATION» OF CONTAINER HANDLING LIFTRUCKS WILL HAPPEN BECAUSE (AT LEAST)
HYBRID POWERING IS ECONOMICALLY MUCH MORE CONVENIENT
Question:WILL THE «ELECTRIFICATION» OF CONTAINER HANDLING LIFTRUCKS PRIVILEDGE
THE HYBRID OR THE FULL ELECTRIC MODALITY?
!
?
FULL ELECTRIC CONTAINER HANDLING LIFTRUCKS ARE UNDER DEVELOPMENTAND MANUFACTURERS THAT ARE ENGAGED IN THIS QUEST SEEM TO PURSUEDIFFERENT TECHNOLOGY PATHS.
CVS FERRARI IS ONE OF THOSE MANUFACTURERS AND ITS DEVELOPMENT PATHTOWARDS A FULL ELECTRIC CONTAINER HANDLING MASTED LIFTRUCK IS CONSISTENTWITH THE HYBRID DESIGN & CONCEPT THAT IS BASED ON THE ELECTRIC POWEREDWINCHED LIFT MECHANISM.
THE PRELIMINARY STUDIES MADE BY CVS FERRARI OVER THE TOTAL COST OFOWNERSHIP OF A FULL ELECTRIC CONTAINER HANDLING LIFTRUCK ARE BASEDON THE IN HOUSE TECHNOLOGY
IT IS VERY LIKELY THAT THE «ELECTRIFICATION» OF THE CONTAINER HANDLING LIFTRUCKSWILL REVIVE THE POPULARITY OF MASTED LIFTRUCKS
WHICH TYPE OF «ELECTRICFIED» POWER SOURCE WILL BE MORE POPULAR IN FUTURE?- HYBRID?
- FULLY ELECTRIC?
In terms of ENVIRONMENTAL IMPACT the FULLY ELECTRIC trucks are «ZERO EMISSIONS»machineries and as such they could be preferrable; although they ultimately have an impacton the power grid and on the pollution it generates.
Yet the economical drive will still probably remain a main factor for the eventual successof the FULLY ELECTRIC Container Handling Trucks, as they will also have to face the issueof the BATTERY CHARGE DURATION and RECHARGE TIME
The belief is that, net of the [VERY IMPORTANT] environmental policies and incentives, theFULL ELECTRIC trucks future affirmation will depend from 3 main factors:
1. Cost of the Electric Power
2. Type (intensity) of application Work Cycle
3. Cost and Life duration of the Battery
MAIN DRIVERS OF SUCCESS OF THE FULLY ELECTRIC CONTAINER HANDLING LITRUCKS
POWER SOURCESHYBRIDFULL ELECTRIC
+
Engine (15,000 w/h life)
Supercapacitors(40,000 w/life)
Li-OnBattery(? w/h life)
The Li-On Battery has sensibly higher costthan the Gen Set + Supercaps
What will happen in the future?Its working life is also not clear yet
Purchase CostFULL ELECTRICPOWER TRUCK
HYBRIDPOWER TRUCK
100 100
200 200
300 300
400 400
500 500
160 120
- CVS FERRARIProduct Price
- CVS FERRARIProduct Price
(expressed in Relative Terms)
Power SourceFuel
Consumption(l/h)
Conv. Ratio (litres to kg)
FuelConsumption
(Kg/h)
Specific FuelConsumption
(g/kWh)
AbsorbedkWh
Energy Cost per Working Hour
(Euro)
CONVENTIONAL 12 0,85 10,2 210 48,57 12,00
HYBRID 7 0,85 5,95 200 29,75 7,00
FULL ELECTRIC ? ?
POWER ABSORBTION OF (AVERAGE) WORK CYCLE
European CountryElectric Energy Cost
(Euro / kWh)
Hourly energy cost per (equivalent) Work Cycle with 20 kWh estimated Power Absorbtion
(Euro)
DENMARK 0,308 6,160
GERMANY 0,298 5,960
BELGIUM 0,275 5,500
ITALY 0,234 4,680
SPAIN 0,288 5,760
SWEDEN 0,196 3,920
GREAT BRITAIN 0,183 3,660
FRANCE 0,171 3,420
NETHERLANDS 0,159 3,180
FINLAND 0,155 3,100
ELECTRIC ENERGY COST AND WORK CYCLE
100
> 20,000 40000
TCO
WORKHOURS
TOTAL COST OF OWNERSHIP(Pa
HYBRID
FULL ELECTRIC
At the present state ofavailable technologies,the FULL ELECTRICmachine could be orcould never be moreeconomical than theHYBRID one.
As the different in price between the HYBRID and the FULL ELECTRIC is relevant whilst thedifference in running costs is variable and notso consistent, the eventual break-even pointis very delayed in time.
The Full Electric machine is s projected to be 60% More expensive than a conventional truck and 25% more expensive than an hybrid truck.
CONCLUSIONS
I. THE HYBRID CONTAINER HANDLING LIFTRUCKS ARE A REALITY. THAT THEY ALREADY SOLIDLY PROMISES MAJOR TOTAL COST OF OWNERSHIP REDUCTIONS OVER THE CONVENTIONAL TECHNOLOGY MACHINES.
II. NET OF THE INCENTIVES THAT SOME ADMINISTRATIONS PROMOTE FOR THEDIFFUSION Of «ZERO EMISSIONS» MACHINES, THE ECONOMIC CONVENIENCE OF THE FULLY ELECTRIC MACHINES DEPENDS FROM SEVERAL FACTORS ANDTHE FUTURE TECHNOLOGIC AND MACROECONOMICS DEVELOPMENTS
THANK YOU FOR YOUR ATTENTION
Davide BertozziDirector – Trade and Development
CVS FERRARI S.p.A.