Traditionally, diesel generators have been the go-to solution, providing reliable power in even the most remote locations. But these machines contribute to high fuel consumption, emissions, and operational costs. As industries embrace a more efficient future, a new player is changing the game: Energy Storage Systems (ESS) or Battery energy storage systems (BESS). Integrating ESS offers a maintainable and efficient alternative. We explore how BESS can transform crane applications, the technology behind it, and why Atlas Copco's solutions are ideal for this purpose.
Handling the power peaks of cranes with ease
Cranes are known for their demanding and highly variable power profiles. Their high-power demands often make them unsuitable for direct grid connections, especially in areas with limited or no mains supply. When a crane lifts a heavy load, it requires a massive surge of power—a "peak load." This sudden demand can put a strain on traditional diesel generators, forcing contractors to oversize their generators to handle these briefs, yet significant, power spikes. This results in the generator running at a low load for most of the day, which is inefficient and leads to higher fuel consumption, increased wear and tear, and a higher Total Cost of Ownership (TCO).
An Enery Storage System, on the other hand, is specifically designed to manage these peak loads. It can instantly discharge stored energy to meet the crane's sudden demand, protecting the generator from strain. When used in a hybrid setup with a smaller, more appropriately sized generator, the ESS allows the generator to run at its most efficient speed.
Modern large cranes, such as those used in ports, require approximately ten times the nominal power to start. This makes the case for hybrid solutions, where energy storage systems complements diesel generators, enabling more efficient operations. By integrating a battery energy storage system, contractors can reduce fuel consumption, emissions, and overall costs while ensuring reliable power delivery.
Atlas Copco's Energy Storage Systems, specifically the ZBC and ZBP models, are ideal for powering tower cranes. These systems include:
- ZBC 1000-1200 Container Battery Pack: A robust and scalable solution designed to meet the high-power demands of tower cranes.
These BESS solutions allow for hybrid setups, where the battery system works in tandem with a generator. This configuration ensures efficient energy use, peak shaving, and reduced reliance on diesel generators.
A more Efficient Job Site
Operational requirements are evolving, and many projects now aim to reduce fuel use and minimize exhaust output. Energy Storage Systems (ESS) offer a practical solution for improving energy efficiency on-site.
Used on their own, ESS units deliver power without combustion or noise—making them suitable for urban areas or nighttime work where sound and air quality limitations may apply. In hybrid setups, battery energy storage system units reduce generator runtime, which lowers fuel consumption and decreases the release of exhaust gases.
Atlas Copco’s ZBC 1000 energy storage system is well-suited for construction and event sites. It helps reduce the number of generators needed, cuts fuel usage, and supports more efficient energy management.
Boosting Efficiency and Lowering TCO
Beyond the environmental benefits, ESS delivers tangible financial advantages. By allowing you to downsize your generator and optimize its performance, you can achieve substantial savings on fuel costs. Moreover, the reduced wear and tear on the generator means longer service intervals and a longer lifespan, lowering maintenance and overhaul costs.
Atlas Copco’s battery energy storage units are also designed for reliability and intelligence. Their ECO Controller™ is the "brain" of the system, monitoring and optimizing the flow of energy from all sources—whether it's a generator, or the grid. It integrates performance data and centralizes all hybrid energy sources. It also communicates seamlessly with components like inverters, batteries, solar charge controllers, energy meters, and third-party monitoring systems. This smart management ensures you are always using the most efficient and cost-effective power source available, all while being able to remotely monitor your equipment in real time with Atlas Copco FleetLink telematics system, optimizing fleet usage, reducing maintenance costs, and saving time and money.
ZBC Energy Storage System for construction crane operation
Choosing the right BESS for tower crane applications
Selecting the appropriate battery energy storage system is crucial for ensuring optimal performance, reducing operational costs, and maximizing the lifespan of the equipment. Below are the key factors to consider when selecting a BESS for crane applications:
1. Proper Sizing. Proper sizing of the ESS or BESS is fundamental to achieving efficiency and cost savings. A hybrid setup, combining a generator with an ESS, or a peak shaving configuration, can significantly enhance performance. When sized correctly, this setup reduces fuel consumption, minimizes generator running hours, and lowers maintenance costs. Conversely, improper sizing can have the opposite effect, leading to increased fuel consumption and reduced durability of both the generator and the ESS. Therefore, careful evaluation of the power requirements is essential to avoid inefficiencies.
2. Peak Power Delivery. The Energy storage system must be capable of delivering the peak power required by the crane during operation. This is a critical consideration, as cranes often experience high power surges, especially during startup. For instance, a typical peak power calculation might look like this:
Peak Power = (1.732 × 400V × 50A) / 1000 = 35 kW
This calculation ensures that the ESS can handle the crane's maximum power demand without compromising performance or reliability.
3. Battery Capacity. In addition to peak power, the battery energy storage system must have sufficient battery capacity to meet the crane's daily energy consumption. This capacity can be determined by using data provided by the customer, such as electricity bills, load profiles, or operational details like working hours and average power usage. By accurately assessing the daily energy requirements, the BESS can be tailored to provide uninterrupted power while minimizing energy waste.
By carefully considering these factors—proper sizing, peak power delivery, and battery capacity—contractors can ensure that their ESS is optimized for crane applications. This not only enhances operational efficiency but also contributes to significant cost savings and a reduced environmental footprint.
Conclusion
The integration of Energy Storage Systems (ESS) into crane applications represents a significant step toward sustainable and efficient operations. By reducing reliance on diesel generators, contractors can lower fuel costs, minimize emissions, and enhance overall performance. Atlas Copco's ZBC and ZBP models, with their advanced energy management and remote monitoring capabilities, are the ideal solutions for this transformation.
As the construction and logistics industries continue to prioritize sustainability, adopting BESS for tower cranes is not just a smart choice, it is a necessary one.
Ready to learn more about how Atlas Copco's Energy Storage Systems can transform your crane operations? Contact us today to discuss a solution tailored to your needs.
Download the application use case
- ESS Crane Application .pdf 323.4 kB, PDF
