Battery storage in tower crane applications

From construction to shipping, BESS offers optimised power solutions

Key takeaways

Tower cranes require short bursts of high power that leave diesel generators idle or underloaded for much of the day, making them well suited to a hybrid BESS and generator setup.
Pairing a BESS with a generator allows the generator to be downsized to cover base load only, reducing fuel consumption, emissions, and operating costs.
Where mains supply is limited, a BESS can act as a standalone solution by peak shaving the grid connection and recharging during periods of low demand.
A BESS can also handle low-power overnight loads such as aviation lights and signboards, further reducing the need for continuous generator use.

Tower cranes power demand

Tower cranes are among the most energy-intensive machines on a construction site, dock or shipyard. Their significant power demand often means they are too powerful to connect directly to the grid. As a result, contractors typically rely on diesel generators to power them. However, operating tower cranes with large diesel generators can be inefficient, result in high emissions, and lead to substantial fuel costs.

The benefits of Battery Energy Storage Systems (BESS)

Short bursts of high power for lifting are required during the operation of tower cranes. During the rest of the time, diesel generators often sit idle or operate underloaded, which is inefficient and can be harmful to equipment. Integrating a Battery Energy Storage System (BESS) with a generator allows for a more optimised power solution. The BESS can support the generator during periods of high demand, enabling the generator to be downsized to cover the base load efficiently.

A battery can be a reliable and more sustainable energy source for powering tower cranes. This setup allows the generator to run more efficiently, reducing fuel consumption and emissions. Additionally, a BESS can be used to handle overnight operations, such as powering aviation lights or sign boards, further reducing the need for continuous generator use.

BESS as a standalone solution

In scenarios where the site has a limited mains connection that is insufficient to power the crane, a BESS can serve as a standalone solution. By ‘peak shaving’ the grid connection, the BESS can provide additional power when the mains supply reaches its limit and recharge during periods of low demand.

This approach not only overcomes capacity constraints but also optimises energy usage, ensuring that the crane operates smoothly without the need for oversized or continuously running generators.

Key sectors

Construction (BS&C): Tower cranes are common on construction sites that often have limited or no mains supply.
Shipping: Dockyards and cargo operations require high-power cranes.

Benefits of BESS in tower crane solutions

Reduce emissions: by decreasing the reliance on diesel generators, emissions can be significantly reduced.
Lower fuel consumption: optimised energy usage leads to lower fuel consumption and therefore reduced carbon footprint.
Reduce fuel costs: lower fuel consumption translates to cost savings.
Downsize/rightsize generators: smaller generators can be used reducing emissions and fuel consumption.
Overcome capacity constraints: BESS can supplement limited mains supply or support generators.

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Example of powering a tower crane with a hybrid power system

Consider a city centre construction site with a tower crane that requires a 500 kVA generator according to the manufacturer's spec sheet. The site operates 24/7 to keep aviation lights and a signboard on, necessitating a continuous power supply all whist adhering to emissions legislation.

Traditional diesel generator solution:

An oversized generator supplied with a load bank to offset the operational issues that occur when a generator is reversed powered. A 500 kVA generator would typically run 24/7, leading to inefficiencies and potential long-term damage due to continuous underloading, while a load bank operation would generate excessive heat and fuel burn.

Hybrid power solution:

A more efficient setup would involve a BESS rated at 500 kVA with a 250kWh capacity, paired with a 500 kVA generator. The battery would handle the crane's load most of the time, as cranes generally have short spikes in power demand. The generator would run only when needed and to recharge the BESS. During off-peak hours, such as nights and weekends, the BESS would power the signboard and aviation lights. This setup ensures that the generator runs more efficiently, reducing fuel consumption, CO2 emissions, local emissions and noise pollution.

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1263 AGG NAM BESS Launch GU EVO_01-BESS-Launch-Greener-Upgrades_SQU

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Implementation considerations

When designing a battery solution, sites would need to consider the following:

Generator sizing: Ensure the generator can handle the daytime load while recharging the BESS.
BESS capacity: Choose a BESS with sufficient kWh to handle short power spikes and maintain continuous operation during low-demand periods.

By integrating BESS with traditional power sources, construction sites, docks or shipyards can achieve significant environmental and economic benefits, ensuring the smooth running of equipment and improving sustainability.

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Battery storage in tower crane applications

Key takeaways

Tower cranes power demand